Wipes having high sustainable content

ABSTRACT

A cleaning wipe having a high sustainable polymer content is provided. The cleaning wipe includes a fibrous layer having fibers of a melt spinnable sustainable polymer; and an abrasive layer having meltblown fibers of a melt spinnable sustainable polymer. The abrasive layer defining an outer surface of the cleaning wipe, and includes a plurality of abrasive structures formed thereon in which the abrasive structures are formed from conglomerated fibers, meltblown shot, fibers having average diameters greater than 4 micrometers and fibers having a tortuous geometry. The melt spinnable sustainable polymer content of the cleaning wipe is at least 50 weight % by weight of the cleaning wipe. A method of preparing the cleaning wipe is also provided.

FIELD

The presently-disclosed invention relates generally to cleaning wipes,and more particularly to cleaning wipes comprised of a spunbond nonwovenlayer and a meltblown layer in which both layers have a high sustainablepolymer content.

BACKGROUND

Abrasive cleaning pads and wipes are commonly used in many cleaningapplications, including personal, home, commercial, and industrialapplications. Traditionally, such cleaning pads and wipes include alayer having an abrasive material for removing so-called “stuck-on”materials that are difficult to remove, and an absorbent layercomprising an absorbent material, such as a sponge, foamed, or cellulosematerial.

However, such traditional cleaning pads and wipes may be expensive, andtherefore unsuitable for a disposable or single use product. To addressthis concern, various wipes have been developed that include amulti-layered construction in which an abrasive layer is formed ofcourse synthetic polymer fibers, and an absorbent layer is formed of afibrous material. An example of such a wipe is described in U.S. PatentPublication No. 2005/0136772 to Chen et al. Chen describes a cleaningwipe or pad having an abrasive layer formed of meltblown syntheticfibers, and an absorbent layer formed of absorbent pulp fibers that aremixed with synthetic meltblown fibers. The presence of the syntheticmeltblown fibers in the absorbent layer helps to improve bonding betweenthe synthetic fibers of the abrasive layer to the synthetic fibers ofthe absorbent layer. Examples of thermoplastic polymers for use inpreparing the synthetic fibers of Chen include polyethylenes,polypropylenes, polyesters, polyamides, polystyrenes, and the like.

These so-called synthetic polymers are generally very stable and canremain in the environment for a long time. Recently, however, there hasbeen a trend to develop articles and products that are consideredenvironmentally friendly and sustainable. As part of this trend, therehas been a desire to produce ecologically friendly products comprised ofincreased sustainable content in order to reduce the content ofpetroleum based materials.

Accordingly, there still exists a need for abrasive cleaning pads andwipes having a high sustainable content.

SUMMARY

One or more embodiments of the invention may address one or more of theaforementioned problems. In one embodiment, aspects of the presentinvention are directed to cleaning wipes or pads (hereinafter referredto as a “cleaning wipe”) for use in cleaning a surface through wiping orscrubbing. More specifically, aspects of the invention are directed to acleaning wipe having a high sustainable polymer content.

Certain embodiments according to the invention provide a multilayercleaning wipe comprising an abrasive layer that is attached to a fibrouslayer, and in which the abrasive layer defines an outer surface of thecleaning wipe, and wherein the sustainable polymer content of thecleaning wipe is at least 50% by weight of the cleaning wipe.

The abrasive layer comprises a meltblown web in which the surface of theweb is characterized as having abrasive structures formed therein. Theabrasive structures comprise conglomerated fibers in which multiplefibers are joined, married, or otherwise fused to adjacent fibers,fibers having average fiber diameters in excess of 4 micrometers,meltblown shot, and fibers having a tortuous geometry in which thefibers are characterized as having twists, kinks, coils, and the like.The process conditions for preparing the meltblown web are selected toproduce a cleaning wipe having a desired level of abrasiveness. Forexample, a meltblown web exhibiting a greater number of abrasivestructures will exhibit a greater degree of coarseness or abrasivenessin comparison to a cleaning wipe having less abrasive structures on thesurface of the meltblown web.

The fibrous layer provides support and integrity for the abrasive layerwhile also supplying a surface having softness and drapeabilty. In oneembodiment, the fibrous layer comprises a plurality of fibers that arebonded to each other to form a coherent web. The fibrous layer may beformed from a wide variety of nonwoven webs including carded webs andspunbond webs. Preferably, the fibrous layer comprises a spunbondnonwoven fabric comprised of a plurality of continuous filaments thatare bonded to each other to form the fabric.

The fibrous layer and abrasive layer both comprise one or moresustainable polymers. In accordance with certain embodiments, thefibrous layer comprises a spunbond nonwoven fabric that is substantiallyfree of synthetic polymer components, such as petroleum-based materialsand polymers. For example, the spunbond nonwoven fabric may have amonocomponent structure in which 100% of the fiber comprises asustainable polymer, or may have a bicomponent structure in which theboth components comprise a sustainable polymer to thus produce a fiberhaving a 100% sustainable polymer content.

In a preferred embodiment, the sustainable polymer comprises polylacticacid (PLA).

A method and system for preparing the cleaning wipe is also provided.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 is a cross-sectional view of a cleaning wipe in accordance withcertain embodiments of the invention;

FIG. 2 is a schematic diagram of the PLA cleaning wipe preparationsystem in accordance with certain embodiments of the invention;

FIGS. 3A-3C are schematic diagrams illustrating positioning of a firstionization source in accordance with certain embodiments of theinvention;

FIGS. 4A and 4B are SEM images of meltblown fibers on a surface of ameltblown web taken at a magnification of 500× and 750×, respectively;

FIGS. 5A and 5B are SEM images of meltblown fibers on a surface of ameltblown web taken at a magnification of 500× and 750×, respectively;and

FIGS. 6A and 6B are SEM images of meltblown fibers on a surface of ameltblown web taken at a magnification of 500× and 750×, respectively.

DETAILED DESCRIPTION

The invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the inventions are shown. Indeed, this inventions may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout. As used inthe specification, and in the appended claims, the singular forms “a”,“an”, “the”, include plural referents unless the context clearlydictates otherwise.

I. Definitions

For the purposes of the present application, the following terms shallhave the following meanings:

The term “fiber” can refer to a fiber of finite length or a filament ofinfinite length.

As used herein, the term “monocomponent” refers to fibers formed fromone polymer or formed from a single blend of polymers. Of course, thisdoes not exclude fibers to which additives have been added for color,anti-static properties, lubrication, hydrophilicity, liquid repellency,etc.

As used herein, the term “multicomponent” refers to fibers formed fromat least two polymers (e.g., bicomponent fibers) that are extruded fromseparate extruders. The at least two polymers can each independently bethe same or different from each other, or be a blend of polymers. Thepolymers are arranged in substantially constantly positioned distinctzones across the cross-section of the fibers. The components may bearranged in any desired configuration, such as sheath-core,side-by-side, pie, island-in-the-sea, and so forth. Various methods forforming multicomponent fibers are described in U.S. Pat. No. 4,789,592to Taniguchi et al. and U.S. Pat. No. 5,336,552 to Strack et al., U.S.Pat. No. 5,108,820 to Kaneko, et al., U.S. Pat. No. 4,795,668 to Kruege,et al., U.S. Pat. No. 5,382,400 to Pike, et al., U.S. Pat. No. 5,336,552to Strack, et al., and U.S. Pat. No. 6,200,669 to Marmon, et al., whichare incorporated herein in their entirety by reference. Multicomponentfibers having various irregular shapes may also be formed, such asdescribed in U.S. Pat. No. 5,277,976 to Hogle, et al., U.S. Pat. No.5,162,074 to Hills, U.S. Pat. No. 5,466,410 to Hills, U.S. Pat. No.5,069,970 to Largman, et al., and U.S. Pat. No. 5,057,368 to Largman, etal., which are incorporated herein in their entirety by reference.

As used herein, the terms “nonwoven,” “nonwoven web” and “nonwovenfabric” refer to a structure or a web of material which has been formedwithout use of weaving or knitting processes to produce a structure ofindividual fibers or threads which are intermeshed, but not in anidentifiable, repeating manner. Nonwoven webs have been, in the past,formed by a variety of conventional processes such as, for example,meltblown processes, spunbond processes, and staple fiber cardingprocesses.

As used herein, the term “meltblown” refers to a process in which fibersare formed by extruding a molten thermoplastic material through aplurality of fine, usually circular, die capillaries into a highvelocity gas (e.g. air) stream which attenuates the molten thermoplasticmaterial and forms fibers, which can be to microfiber diameter.Thereafter, the meltblown fibers are carried by the gas stream and aredeposited on a collecting surface to form a web of random meltblownfibers. Such a process is disclosed, for example, in U.S. Pat. No.3,849,241 to Buntin et al.

As used herein, the term “machine direction” or “MD” refers to thedirection of travel of the nonwoven web during manufacturing.

As used herein, the term “cross direction” or “CD” refers to a directionthat is perpendicular to the machine direction and extends laterallyacross the width of the nonwoven web.

As used herein, the term “spunbond” refers to a process involvingextruding a molten thermoplastic material as filaments from a pluralityof fine, usually circular, capillaries of a spinneret, with thefilaments then being attenuated and drawn mechanically or pneumatically.The filaments are deposited on a collecting surface to form a web ofrandomly arranged substantially continuous filaments which canthereafter be bonded together to form a coherent nonwoven fabric. Theproduction of spunbond non-woven webs is illustrated in patents such as,for example, U.S. Pat. Nos. 3,338,992; 3,692,613, 3,802,817; 4,405,297and 5,665,300. In general, these spunbond processes include extrudingthe filaments from a spinneret, quenching the filaments with a flow ofair to hasten the solidification of the molten filaments, attenuatingthe filaments by applying a draw tension, either by pneumaticallyentraining the filaments in an air stream or mechanically by wrappingthem around mechanical draw rolls, depositing the drawn filaments onto aforaminous collection surface to form a web, and bonding the web ofloose filaments into a nonwoven fabric. The bonding can be any thermalor chemical bonding treatment, needling, or hydroentangling, withthermal point bonding being preferred.

As used herein, the term “thermal point bonding” involves passing amaterial such as one or more webs of fibers to be bonded between aheated calender roll and an anvil roll. The calender roll is typicallypatterned so that the fabric is bonded in discrete point bond sitesrather than being bonded across its entire surface.

As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as, for example, block,graft, random and alternating copolymers, terpolymers, etc. and blendsand modifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” shall include all possible geometricalconfigurations of the material, including isotactic, syndiotactic andrandom symmetries.

In the context of the present invention, the term “sustainable” refersto a material derived from natural processes such agriculture orforestry that are renewed or replenished to remain available for futuregenerations. Sustainable polymers can thus be contrasted with petroleumsourced polymers (also referred to as synthetic polymers) where thesupply of petroleum is not naturally replenished in a reasonable lengthof time. Sustainable polymers suitable for embodiments of the presentinvention typically have a sustainable content that is at least 25weight percent on the weight percent of the sustainable polymer content,and more typically at least 50 weight percent, with a weight percent ofat least 75%, and at least 90% being somewhat more typical. In apreferred embodiment, the sustainable polymer component comprises from90 to 100 weight percent of sustainable content. In addition,sustainable polymers for use in the present invention are those that aremelt spinnable, and thus can be used in melt spinning processes, such asspunbonding and meltblowing processes.

In some embodiments, the sustainable polymer content may comprisebio-based or biodegradable polymer materials. “Biodegradable” refers toa material or product which degrades or decomposes under environmentalconditions that include the action of microrganisms. Thus a material isconsidered as biodegradable if a specified reduction of tensile strengthand/or of peak elongation of the material or other critical physical ormechanical property is observed after exposure to a defined biologicalenvironment for a defined time. Depending on the defined biologicalconditions, a product comprised of a bio-based material might or mightnot be considered biodegradable.

A special class of biodegradable product made with a bio-based materialmight be considered as compostable if it can be degraded in a composingenvironment. The European standard EN 13432, “Proof of Compostability ofPlastic Products” may be used to determine if a fabric or film comprisedof sustainable content could be classified as compostable.

Embodiments of the present invention are directed to a cleaning wipehaving a high sustainable polymer content. Preferably, cleaning wipes inaccordance with the embodiments of the present invention have asustainable polymer content of at least 50% by weight of the cleaningwipe, such as comprising a sustainable polymer content (“SPC”) that isat least 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% by weight of thecleaning wipe. In a preferred embodiment, the cleaning wipes inaccordance with the invention may have a 100% SPC content by weight ofthe cleaning wipe.

As used herein, “100% SPC” may also include up to 5% additives includingadditives and/or masterbatches of additives to provide, by way ofexample only, color, softness, slip, antistatic protection, lubricity,hydrophilicity, liquid repellency, antioxidant protection and the like.In this regard, the abrasive layer may comprise 95-100% SPC, such asfrom 96-100% SPC, 97-100% SPC, 98-100% SPC, 99-100% SPC, etc. When suchadditives are added as a masterbatch, for instance, the masterbatchcarrier may primarily comprise the same or similar sustainable polymerin order to facilitate processing and to maximize sustainable contentwithin the formulation.

With reference to FIG. 1, a cleaning wipe in accordance with at leastone embodiment of the invention is shown and designated by referencecharacter 10. As discussed in greater detail below, the cleaning wipecomprises two or more layers. In the illustrated embodiment, thecleaning wipe 10 includes an abrasive layer 12, which defines an outersurface 14 of the wipe, and a second fibrous layer 16. The secondfibrous layer 16 includes a first outer surface that is attached to anopposite surface of the abrasive layer, and a second outer surface thatin some embodiments may define a second outer surface of the cleaningwipe. As explained below, abrasive layer 12 and second fibrous layer 16both comprise materials having a high sustainable polymer content.

Although the illustrated embodiment shows a cleaning wipe having twolayers, it should be recognized that in some embodiments the cleaningwipe may include additional layers, such as three or more layers, fouror more layers, five or more layers, etc.

II. The Abrasive Layer

The abrasive layer 12 comprises a meltblown web that has been processedin order to have a desired abrasiveness for a given application. Forinstance, the materials and processing conditions for the meltblown webmay be selected and designed with a view to the ultimate end use of thecleaning wipe. For example, a cleaning wipe for cleaning a wood surfacemay include an abrasive layer which is softer or less rough than acleaning wipe designed for use on a kitchen surface, such as a stovetop.

The outer surface of the abrasive layer is characterized by the presenceof abrasive structures. In general, the greater number of abrasivestructures that are present on the surface of the meltblown web, thegreater the coarseness or abrasiveness of the surface. Typically, theouter surface includes two or more abrasive structures comprising 1)conglomerated fibers in which multiple fibers are joined, married, orotherwise fused to adjacent fibers, 2) meltblown shot, 3) fibers havingaverage diameters greater than 4 micrometers and 4) fibers having atortuous geometry in which the fibers are characterized as havingtwists, kinks, coils, loops, and the like. In this regard, FIGS. 4A-6Bare SEM images of the surface of three different meltblown webs havingdifferent degrees of abrasiveness. As can be seen in the images, thesurfaces of all three meltblown webs may be characterized as havingconglomerated fibers, meltblown shot, and fibers having a tortuousgeometry.

Generally, in the manufacture of conventional meltblown materials, highvelocity air is typically used to attenuate the polymeric strands tocreate fine, thin fibers. In embodiments of the present invention, ameltblown web having increased abrasiveness may be created by adjustingone or more of the meltblown process conditions, such as airtemperature, air volume, distance of the spinnerets to the webcollection surface, and the like to thereby produce abrasive structureson surface of the meltblown web. For example, in one embodiment, anabrasive meltblown web may be produced by adjusting conditions of theair flow system, such as by increasing the air flow area or otherwisedecreasing the velocity of the air stream immediately adjacent themolten polymeric strands as they emerge from the meltblown die head. Byadjusting the air flow it is possible to prevent or retard substantialattenuation of the fiber diameter (or reduce the degree of fiberattenuation), which may increase fiber coarseness, which may thenincrease the abrasiveness of the layer formed by the fibers.

In addition, process conditions, such as airflow, may be used to createso-called “shot” within the meltblown web. Shot refers to portions ofthe web where individual meltblown fibers have combined or conglomeratedduring the meltblown process to produce large, uneven globules ofpolymer within the meltblown web. In conventional meltblowing processes,the presence of shot would be highly undesirable. However, in thepresent invention, the shot may help produce increased abrasiveness androughness in the meltblown web. In some embodiments, airflow near thedie exit may be used to agitate and spread the polymeric fibers in amanner that may be highly non-uniform on the forming belt. The largedegree of non-uniformity of the lay-down of coarse meltblown fibers mayresult in forming a meltblown web having variations in thickness andvariations in basis weight across the surface of the web, i.e., anuneven surface may be created on the web, which may increase theabrasiveness of the layer formed by the fibers.

Further, non-uniform spread of the fibers during formation of themeltblown web may create a web with increased void space within themeltblown web. For example, an open network of fibers may be formedwhich may have open voids that occupy a substantial portion of thelayer. For instance, the void volume of the abrasive layer may begreater than about 10%, particularly greater than about 50%, and moreparticularly greater than about 60% of the volume of the material. Theseopen void materials may inherently have good scrubbing properties.

In addition to adjusting the process conditions, or in combination withadjusting process conditions, an abrasive meltblown web may be preparedby selection of sustainable polymers based on the molecular weight ofthe polymer. In this way, the median and mean fiber size of themeltblown fibers can be increased so that a mixture of fibers havinglarger diameters may be produced. In addition, larger fiber diametersmay result in an increase in conglomeration of fibers and/or productionof shot within the meltblown web. As noted previously, larger fibers mayalso result in an increase in open void volume within the meltblown web.

As noted above, the abrasive layer preferably has a high sustainablepolymer content. Suitable materials for use in preparing the meltblownfibers of the abrasive layer may include any sustainable polymer that ismelt spinnable and suitable for preparing a meltblown web.

Nonlimiting examples of sustainable polymers may include polymersdirectly produced from organisms, such as polyhydroxyalkanoates (e.g.,poly(beta-hydroxyalkanoate),poly(3-hydroxybutyrate-co-3-hydroxyvalerate, NODAX™), and bacterialcellulose; polymers extracted from plants and biomass, such aspolysaccharides and derivatives thereof (e.g., gums, cellulose,cellulose esters, chitin, chitosan, starch, chemically modified starch),proteins (e.g., zein, whey, gluten, collagen), lipids, lignins, andnatural rubber; and current polymers derived from naturally sourcedmonomers and derivatives, such as bio-polyethylene, bio-polypropylene,polytrimethylene terephthalate, polylactic acid, NYLON 11, alkyd resins,succinic acid-based polyesters, and bio-polyethylene terephthalate.

In a preferred embodiment, the sustainable polymer may includepolylactic acid and bio-based derived polyethylene. Generally,polylactic acid based polymers are prepared from dextrose, a source ofsugar, derived from field corn. In North America corn is used since itis the most economical source of plant starch for ultimate conversion tosugar. However, it should be recognized that dextrose can be derivedfrom sources other than corn. Sugar is converted to lactic acid or alactic acid derivative via fermentation through the use ofmicroorganisms. Thus besides corn, other agricultural based sugarsources may be used including rice, sugar beets, sugar cane, wheat,cellulosic materials, such as xylose recovered from wood pulping, andthe like. Examples of suitable PLA resins for preparing the meltblownweb are available from NatureWorks under the product name PLA Grades6201 and 6252. In additional suitable polylactic acid resins may also beavailable from Corbion of Arkelsedijk 46, 4206 A C Gorinchem.

Similarly, bio-based polyethylene can be prepared from sugars that arefermented to produce ethanol, which in turn is dehydrated to provideethylene.

In some embodiments, the meltblown fibers may comprise fibers comprisinga blend of a sustainable polymer and a synthetic polymer. For example,WO 2015/112844, the contents of which are hereby incorporated byreference, describes a meltblown nonwoven comprising reclaimed meltblownfibers that are prepared by subjecting bicomponent fibers having asynthetic polymer component, such as polypropylene or polyethylene, anda sustainable polymer component, such as PLA, to a vis-breaking processin which the synthetic polymer component and sustainable polymercomponent are vis-broken to reduce their average molecular weight.Preferably, the vis-broken blend has an MFR to make it useful forpreparation of meltblown nonwoven webs. In one embodiment, the resultingvis-broken blend has an MFR of at least about 400 to 2,500, andpreferably from about 500 to 2,000, and more preferably about 700 to1,800.

The resulting vis-broken resin is then suitable for preparation ofmeltblown fibers. The ratio of the synthetic polymer component to thesustainable polymer component in the meltblown web may range from about10% synthetic polymer component to 90% sustainable polymer component to80% synthetic polymer component to 20% sustainable polymer component,and more preferably from 30% synthetic polymer component to 70%sustainable polymer component to 70% synthetic polymer component to 30%sustainable polymer component. In some embodiments, the reclaimed blendcomprising the synthetic polymer component and the sustainable polymercomponent may be blended with virgin polymer (never used) to form themeltblown fibers.

In accordance with certain embodiments, the abrasive layer comprises anonwoven fabric comprising PLA meltblown fibers, and that issubstantially free of synthetic polymer components, such aspetroleum-based materials and polymers. For example, the abrasive layermay comprise meltblown fibers having a 100% sustainable polymer content.

In a preferred embodiment, the meltblown fibers of the abrasive layercomprise 100% PLA. As in the definition of “100% SPC,” a “100% PLA”fiber may include up to 5% additives including additives and/ormasterbatches of additives to provide, by way of example only, color,softness, slip, antistatic protection, lubricity, hydrophilicity, liquidrepellency, antioxidant protection and the like. For example, theabrasive layer may comprise 95-100% PLA, such as from 96-100% PLA,97-100% PLA, 98-100% PLA, 99-100% PLA, etc. In addition, when suchadditives are added as a masterbatch, for instance, the masterbatchcarrier may primarily comprise a PLA polymer in order to facilitateprocessing and to maximize sustainable content within the formulation.

Meltblown webs prepared in accordance with embodiments of the presentinvention may have a wide variety of basis weight ranges depending onthe desired application. For example, meltblown webs and laminatesincorporating such meltblown webs may have basis weights ranging fromabout 0.25 to 20 g/m², and in particular, from about 1.5 to 3 g/m². Insome embodiments, the meltblown webs may have basis weights ranging from1 to 400 g/m², for example, from about 15 to 400 g/m².

As discussed above, the meltblowing process may be selectively adjustedto provide a meltblown web having a desired level of abrasiveness. Ingeneral, the abrasiveness of the surface of the abrasive layercorrelates with the kinetic coefficient of friction for the surfacelayer. For example, an abrasive layer exhibiting a kinetic coefficientof friction that is from about 0.2 to 0.49 can be classified asproviding a cleaning wipe having a fine surface, whereas an abrasivelayer exhibiting a kinetic coefficient of friction that is greater than1.0 can be classified as having a very coarse surface. Table 1 belowsummarizes the relevant classes of cleaning wipes in accordance withembodiments of the invention.

In general, individual meltblown fibers may have diameters of less than15 microns, and in particular, diameters of less than 10 microns. In oneembodiment, the meltblown fibers have diameters from about 3 to 0.5microns, and in particular, from about 1 to 2 microns. In someembodiments, the meltblown fibers may have diameters from about 3 toless than 0.5 microns, and in particular from about 1 to 3 microns.However, depending on the meltblown processing conditions and thedesired level of abrasiveness, the meltblown fibers may advantageouslyconglomerated with adjacent fibers to provide a married/fused meltblownfiber having an increased diameter. Table 1 provides average fiberdiameter ranges for each of cleaning wipe classifications.

As noted above, the surface of the meltblown web is characterized by thepresence of abrasive structures that may result from conglomeratedfibers and/or fibers having larger diameters. In one embodiment, atfibers forming the meltblown web have an average fiber diameter of about4 micrometers or greater, and in particular, about 6 micrometers, andmore particularly, about 8 micrometers. In general, the wipeclassification will depend on the diameter of the meltblown fibers. Forexample, a cleaning wipe that is considered to have a “fine” abrasivesurface will typically have average fiber diameters from about 4 to 8.5micrometers, and in particular, from about 6 to 8 micrometers. Acleaning wipe that is considered to have a “medium” abrasive surfacewill typically have average fiber diameters from about 8.5 to 10.5micrometers, and in particular, from about 9.0 to 10 micrometers. Acleaning wipe that is considered to have a “course” abrasive surfacewill typically have average fiber diameters from about 10.5 to 12.5micrometers, and in particular, from about 11 to 12 micrometers.Finally, a cleaning wipe that is considered to have a “very coarse”abrasive surface will typically have average fiber diameters from about12.5 to 25 micrometers, and in particular, from about 13 to 20micrometers.

TABLE 1 Classification of Abrasiveness correlated to the KineticCoefficient of Friction Wipe Kinetic Coefficient Average meltblown fiberrange Classification of Friction (micrometers) Fine 0.2-0.49 4.0-8.5Medium 0.5-0.79  8.5-10.5 Coarse 0.8-0.99 10.5-12.5 Very Coarse 1.0 andgreater Greater than 12.5

As discussed in greater detail below, the Kinetic Coefficient ofFriction is measured according to Method C-1231 with the exception thatwhen conducting the measurement, two identical webs are positionedopposite each other in a face-to-face relation, and then the measurementprocedure is performed. For example, in determining the Kineticcoefficient of friction of the meltblown web (i.e., abrasive layer), twoidentical samples of the meltblown web are positioned face-to-face.

III. Fibrous Layer

In the embodiment illustrated in FIG. 1, the fibrous layer 16 includesan inner surface 18 that is joined to the abrasive layer, and anopposite surface 20 that defines a second outer surface 22 of thecleaning wipe 10. The fibrous layer provides support and integrity forthe abrasive layer while also supplying a surface having softness anddrapeabilty.

In one embodiment, the fibrous layer comprises a plurality of fibersthat are bonded to each other to form a coherent web, which helps toprovide structural and integrity to the abrasive layer. The fibrouslayer may be formed from a wide variety of nonwoven webs includingcarded webs, spunbond webs, and a composite structure having aspunbond/meltblown/spunbond (SMS) configuration. In this embodiment, themeltblown layer would not need to be processed under conditions toinclude abrasive structures. For example, the meltblown layer mayprimarily comprise fine meltblown fibers having diameters that aretypically less than 5 micrometers. In addition, such an SMS structuremay also provide liquid barrier properties to prevent a liquid on theabrasive side of the cleaning wipe from passing through the fibrouslayer. In a preferred embodiment, the fibrous layer comprises a spunbondnonwoven fabric comprised of a plurality of continuous filaments thatare bonded to each other to form the fabric.

As discussed above, the fibrous layer has a high sustainable polymercontent. In accordance with certain embodiments, the fibrous layercomprises a spunbond nonwoven fabric that is substantially free ofsynthetic polymer components, such as petroleum-based materials andpolymers. For example, the spunbond nonwoven fabric may have amonocomponent structure in which 100% of the fiber comprises asustainable polymer, or may have a bicomponent structure in which theboth components comprise a sustainable polymer to thus produce a fiberhaving a 100% sustainable polymer content.

Suitable materials for use in preparing the spunbond nonwoven fabric ofthe fibrous layer may include any sustainable polymer that is meltspinnable and suitable for preparing a spunbond nonwoven fabric. In thisregard, it is noted that many of the same sustainable polymers that arediscussed above with respect to the meltblown web, may also be used forpreparing the spunbond nonwoven fabric provided such polymers aresuitable for spunbond applications.

In some embodiments, sustainable polymers for use in the spunbondnonwoven fabric may be derived from an aliphatic component possessingone carboxylic acid group (or a polyester forming derivative thereof,such as an ester group) and one hydroxyl group (or a polyester formingderivative thereof, such as an ether group) or may be derived from acombination of an aliphatic component possessing two carboxylic acidgroups (or a polyester forming derivative thereof, such as an estergroup) with an aliphatic component possessing two hydroxyl groups (or apolyester forming derivative thereof, such as an ether group).

The term “aliphatic polyester” covers—besides polyesters which are madefrom aliphatic and/or cycloaliphatic components exclusively alsopolyesters which contain besides aliphatic and/or cylcoaliphatic unitsaromatic units, as long as the polyester has substantial sustainablecontent. As noted above, the sustainable content is typically at least25 weight %, and more preferably 75 weight % and even more preferably atleast 90 weight %.

Polymers derived from an aliphatic component possessing one carboxylicacid group and one hydroxyl group are alternatively calledpolyhydroxyalkanoates (PHA). Examples thereof are polyhydroxybutyrate(PHB), poly-(hydroxybutyrate-co-hydroxyvaleterate) (PHBV),poly-(hydroxybutyrate-co-polyhydroxyhexanoate) (PHBH), polyglycolic acid(PGA), poly-(epsilon-caprolactione) (PCL) and preferably polylactic acid(PLA).

Examples of polymers derived from a combination of an aliphaticcomponent possessing two carboxylic acid groups with an aliphaticcomponent possessing two hydroxyl groups are polyesters derived fromaliphatic diols and from aliphatic dicarboxylic acids, such aspolybutylene succinate (PBSU), polyethylene succinate (PESU),polybutylene adipate (PBA), polyethylene adipate (PEA),polytetramethy-lene adipate/terephthalate (PTMAT).

In a preferred embodiment, the fibers of the spunbond nonwoven fabriccomprises 100% PLA. As used herein, “100% PLA” may also include up to 5%additives including additives and/or masterbatches of additives toprovide, by way of example only, color, softness, slip, antistaticprotection, lubricity, hydrophilicity, liquid repellency, antioxidantprotection and the like. In this regard, the nonwoven may comprise95-100% PLA, such as from 96-100% PLA, 97-100% PLA, 98-100% PLA, 99-100%PLA, etc. When such additives are added as a masterbatch, for instance,the masterbatch carrier may primarily comprise PLA in order tofacilitate processing and to maximize sustainable content within theformulation.

Generally, polylactic acid based polymers are prepared from dextrose, asource of sugar, derived from field corn. In North America corn is usedsince it is the most economical source of plant starch for ultimateconversion to sugar. However, it should be recognized that dextrose canbe derived from sources other than corn. Sugar is converted to lacticacid or a lactic acid derivative via fermentation through the use ofmicroorganisms. Lactic acid may then be polymerized to form PLA.Examples of such high performance PLA resins include L105, L130, L175,and LX175, all from Corbion of Arkelsedijk 46, 4206 A C Gorinchem, theNetherlands. Other examples of PLA resins include Nature Works PLA GradePLA 6752 and NatureWorks Grade 6202.

Thus, besides corn other agricultural based sugar source could be usedincluding rice, sugar beets, sugar cane, wheat, cellulosic materials,such as xylose recovered from wood pulping, and the like.

In some embodiments, the nonwoven fabrics may be biodegradable.

“Biodegradable” refers to a material or product which degrades ordecomposes under environmental conditions that include the action ofmicroorganisms. Thus, a material is considered as biodegradable if aspecified reduction of tensile strength and/or of peak elongation of thematerial or other critical physical or mechanical property is observedafter exposure to a defined biological environment for a defined time.Depending on the defined biological conditions, a fabric comprised ofPLA might or might not be considered biodegradable.

In accordance with certain embodiments, for example, the spunbondnonwoven fabric may comprise bicomponent fibers. In some embodiments,for instance, the bicomponent fibers may comprise a side-by-sidearrangement. However, in other embodiments, for example, the bicomponentfibers may comprise a sheath and a core. In some embodiments, thebicomponent fibers can be made using sheath/core bicomponent fiberswhere the core comprises PLA, and the sheath comprises polymersincluding, but not limited to, polypropylene (PP), polyethylene (PE),polyethylene terephthalate (PET) and/or the like. However, in otherembodiments, the nonwoven fabric may comprise bicomponent fibers wherethe core comprises polymers including, but not limited to, PP, PE, PETand/or the like, and the sheath comprises PLA.

In such embodiments, for instance, the sheath may comprise PLA. Infurther embodiments, for example, the core may comprise at least onesynthetic polymer component. For example, the PLA continuous filamentsmay comprise a PLA sheath, and a synthetic polymer, such as PP, PE, PET,or any combination thereof.

In other embodiments, the core may comprise PLA in which the PLA mayhave a higher or lower melting temperature than the PLA of the sheath.In one embodiment, the bicomponent fibers may comprise PLA/PP reversebicomponent fibers, PLA/PE reverse bicomponent fibers, PLA/PET reversebicomponent fibers, or PLA/PLA reverse bicomponent fibers.

In certain embodiments, for instance, the bicomponent fibers maycomprise PLA/PLA bicomponent fibers such that the sheath comprises afirst PLA grade, the core comprises a second PLA grade, and the firstPLA grade and the second PLA grade are different (e.g., the first PLAgrade has a higher melting point than the second PLA grade). Forexample, in one embodiment, the core may comprise a PLA having a lower %D isomer of polylactic acid than that of the % D isomer PLA polymer usedin the sheath. The PLA polymer with lower % D isomer will show higherdegree of stress induced crystallization during spinning while the PLApolymer with higher D % isomer will retain a more amorphous state duringspinning. The more amorphous sheath will promote bonding while the coreshowing a higher degree of crystallization will provide strength to thefiber and thus to the final bonded web. In one particular embodiment,the Nature Works PLA Grade PLA 6752 with 4% D Isomer can be used as thesheath while NatureWorks Grade 6202 with 2% D Isomer can be used as thecore.

By way of example only, the sheath may comprise PLA; the core maycomprise at least one synthetic polymer component. The PLA grade of thestarting material should have proper molecular properties to be spun inspunbond processes. Examples of suitable include PLA grades suppliedfrom NatureWorks LLC, of Minnetonka, MN 55345 such as, grade 6752D,6100D, and 6202D believed to be produced as generally following theteaching of U.S. Pat. Nos. 5,525,706 and 6,807,973 both to Gruber et al.

Examples of synthetic polymer components include polyolefins, such as PPand PE, blends of polyolefins, such as those taught by Chester et al. inUS Patent Publication No. 2014/0276517 incorporated herein in itsentirety by reference, and polyesters, such as PET, polytrimethyleneterephthalate (PTT), and polybutylene terephthalate (PBT), polystyrenes,and the like.

A wide variety of polypropylene polymers may be used in the startingmaterial including both polypropylene homopolymers and polypropylenecopolymers. In one embodiment, the polypropylene of the startingmaterial may comprise a metallocene or

Ziegler Natta catalyzed propylene polymers.

Examples of Ziegler Natta polypropylenes that may be used in embodimentsof the present invention include TOTAL®3866 polypropylene from TotalPetrochemicals USA, INC of Houston, Tex.; Braskem CP 360H polypropylenefrom Braskem America of Philadelphia, Pa.; ExxonMobil PD 3445 fromExxonMobil of Houston, Tex.; Sabic 511A from Sabic of Sittard, TheNetherlands; and Pro-fax PH 835 from Basell Polyolefins of Wilmington,Del. Examples of suitable metallocene polypropylenes may include TOTAL®M3766 polypropylene from Total Petrochemicals USA, INC of Houston, Tex.;TOTAL® MR 2001 polypropylene from Total S.A. of Courbevoie, France;ACHIEVE® 3754 polypropylene from ExxonMobil of Houston, Tex.; andACHIEVE® 3825 polypropylene from ExxonMobil of Houston, Tex.

For example, in one embodiment, the spunbond nonwoven fabric maycomprise a bicomponent fiber having a PLA core, such as a corecomprising NatureWorks PLA Grade 6202 and a polyolefin sheath, such as asheath comprising a polypropylene available from LyondellBassell underthe product name HP561R.

In accordance with certain embodiments, for example, the spunbondnonwoven fabric may have a basis weight from about 7 gsm to about 150gsm. In other embodiments, for instance, the fabric may have a basisweight from about 8 gsm to about 70 gsm. In certain embodiments, forexample, the fabric may comprise a basis weight from about 10 gsm toabout 50 gsm. In further embodiments, for instance, the fabric may havea basis weight from about 11 gsm to about 30 gsm. As such, in certainembodiments, the fabric may have a basis weight from at least about anyof the following: 7, 8, 9, 10, and 11 gsm and/or at most about 150, 100,70, 60, 50, 40, and 30 gsm (e.g., about 9-60 gsm, about 11-40 gsm,etc.).

According to certain embodiments, for example, the fibers may have alinear mass density from about 1 dtex to about 5 dtex. In otherembodiments, for instance, the fibers may have a dtex from about 1.5dtex to about 3 dtex. In further embodiments, for example, the fibersmay have a linear mass density from about 1.6 dtex to about 2.5 dtex. Assuch, in certain embodiments, the fibers have a linear mass density fromat least about any of the following: 1, 1.1, 1.2, 1.3, 1.4, 1.5, and 1.6dtex and/or at most about 5, 4.5, 4, 3.5, 3, and 2.5 dtex (e.g., about1.4-4.5 dtex, about 1.6-3 dtex, etc.).

In some embodiments, spunbond nonwoven fabrics for use in someembodiments of the invention may be characterized by an area shrinkageof less than 5%. In further embodiments, for example, the spunbondnonwoven fabrics may be characterized by an area shrinkage of less than2%.

IV. Addition of an Alkane Sulfonate

In some embodiments, one or more of the spunbond nonwoven fabric of thefibrous layer, or the meltblown web of the abrasive layer may include atleast one alkane sulfonate. It is believed that inclusion of an alkanesulfonate in both the meltblown web and the spunbond nonwoven fabric mayhelp improve bonding between the meltblown fibers and the spunbondfibers. As a result, the cleaning wipe having the alkane sulfonate mayexhibit improved integrity during use. In addition to the abovediscussed advantage, it has also been found that the inclusion of thealkane sulfonate helps to improve the strength and toughness of thespunbond nonwoven fabric.

The at least one alkane sulfonate typically comprises an alkane chainhaving from C₁₀-C₁₈, and wherein at least one of the carbons of thealkane chain includes a sulfonate moiety. In a preferred embodiment, theat least one alkane sulfonate comprises a secondary alkane sulfonate. Inparticular, the at least one alkane sulfonate/secondary alkane sulfonatemay comprise a sulfonic acid, C13-C17-secondary alkane, sodium salt.

The alkane chain is generally linear although some chains may includesome minor branching (e.g., C₁-C₄ side chain branching). Typically, thealkane chain will have from 10 to 18 carbon atoms, with an alkane chainlength of 14 to 17 carbon atoms being somewhat more preferred. Thealkane sulfonate may include both mono- and disulfonic acids. However,the amount of monosulfonic acids in the secondary alkane sulfonate maygenerally be greater than 90%.

In one embodiment, the at least one alkane sulfonate/secondary alkanesulfonate has one of the following structures:

wherein m+n is a number between 7 and 16, and X is independently a C₁-C₄alkyl or absent. In a preferred embodiment, the alkanesulfonate/secondary alkane sulfonate has the following structure:

wherein m+n is a number between 8 and 15, and more preferably m+n is anumber between 11 and 14. The alkane sulfonate typically comprises asalt of sodium or potassium, but other cations could be used, such as asalt of calcium or magnesium. Alternatively, a quaternary ammoniumcomprised of modified fatty alkyl substrates such as those based on cocoor stearyl substrates could be used. Such quaternary amines areavailable from Air Products and Chemicals, Inc. of Allentown, Pa.18195-1501, USA.

In one embodiment, the alkane sulfonate/secondary alkane sulfonate maybe provided in a masterbatch carrier resin. For example, in oneembodiment, the secondary alkane sulfonate is provided in a PLA polymercarrier resin that is blended with the PLA prior to spinning of thefibers. Typically, the amount of alkane sulfonate, and in particular, asecondary alkane sulfonate, in the PLA masterbatch is from about 5 to 25weight percent based on the total weight of the masterbatch, with anamount from 10 to 20 weight percent being somewhat more typical. Themasterbatch may also include additional additives, such as one or morecompatibilizers. A commercial example of a secondary alkane sulfonatethat may be used in embodiments of the claimed invention includesSUKANO® under the product name 5546-Q1, which is a C14-C17 secondaryalkane sulfonate sodium salt in a PLA masterbatch. One skilled in theart would recognize that design of a masterbatch for a secondary alkanesulfonate is a compromise between maximizing the use of PLA resins withvery similar melt flow as observed for the base resin of the fiber, suchas, for example, NatureWorks 6202D or 6252 D (Melt Index g/10 minutes(210° C.) 15-30 or 15, respectively, and the ease of suspending thesecondary alkane sulfonate in a PLA polymer. Thus, a suitablemasterbatch may be comprised of a PLA grade such as Nature Works 6362Dwith a higher melt Index (Melt Index g/10 minutes (210° C.) of 70-85.

When present in the meltblown web, the amount of the alkanesulfonate/secondary alkane sulfonate may range from about 0.0125 weightpercent to about 3 weight percent, based on the total weight of themeltblown web, and in particular, from about 0.25 to 2.5 weight percent,and more particularly, from about 0.5 to about 3 weight percent, basedon the total weight of the meltblown web.

In one embodiment, the fibrous layer comprises a spunbond nonwovenfabric comprising a plurality of fibers that are bonded to each other toform a coherent web, and wherein the plurality fibers comprise a blendof a PLA resin and at least one alkane sulfonate/secondary alkanesulfonate. As explained in greater detail below, the inclusion of analkane sulfonate in the PLA resin improves the strength and toughness ofthe fabric in comparison to an identical fabric that does not includethe alkane sulfonate.

The amount of the alkane sulfonate/secondary alkane sulfonate in thespunbond fibers will generally depend on where the alkane sulfonate ispresent in the structure of the fibers, and the final desired propertiesof the nonwoven fabric. In general, the amount of the alkanesulfonate/secondary alkane sulfonate may range from about 0.0125 weightpercent to about 2.5 weight percent, based on the total weight of thepolymeric component of the fiber in which the alkane sulfonate ispresent. For example, in monocomponent fibers the weight percent of thealkane sulfonate/secondary alkane sulfonate in the fibers will be basedon the total weight of the fiber. In such a case, the amount alkanesulfonate may range from about 0.0125 weight percent to about 2.5 weightpercent, based on the total weight of the fiber. However, in the case ofa bicomponent fiber, the weight percent of the alkanesulfonate/secondary alkane sulfonate will be based on the total weightof the component in which the y alkane sulfonate/secondary alkanesulfonate is present. For example, in the case of a bicomponent fiber inwhich the alkane sulfonate/secondary alkane sulfonate is only present inthe sheath, the weight percent of the secondary alkanesulfonate/secondary alkane sulfonate in the fiber may range from about0.0125 weight percent to about 2.5 weight percent, based on the totalweight of the sheath, which for a bicomponent fabric having a sheath tocore weight ratio of 30:70 results in a weight percent of the alkanesulfonate that is from 0.0375 to 0.750, based on the total weight of thefiber.

In one embodiment, the amount of the alkane sulfonate/secondary alkanesulfonate may be at least about any one of the following: at least0.0125, at least 0.0250, at least 0.0375, at least 0.050, at least0.0625, at least 0.075, at least 0.100, at least 0.125, at least 0.150,at least 0.1875, at least 0.2, at least 0.2475, at least 0.25, at least0.3 at least 0.375, at least 0.40, at least 0.495, at least 0.50, atleast 0.60, at least 0.80, at least 0.9904, at least 1.0, at least 1.25,at least 1.2375, at least 1.5, at least 1.875, at least 2.0, and atleast 2.50, based on the total weight of the polymeric component of thefiber in which the alkane sulfonate/secondary alkane sulfonate ispresent. In other embodiments, the amount of the alkanesulfonate/secondary alkane sulfonate may be less than about any one ofthe following: 0.0250, 0.0375, 0.050, 0.0625, 0.075, 0.100, 0.125,0.150, 0.1875, 0.2, 0.2475, 0.25, 0.3, 0.375, 0.40, 0.495, 0.50, 0.60,0.80, 0.9904, 1.0, 1.25, 1.2375, 1.5, 1.875, 2.0, and 2.50. It shouldalso be recognized that the amount of the alkane sulfonate/secondaryalkane sulfonate present in a polymer component of the fiber alsoencompasses ranges between the aforementioned amounts.

In a preferred embodiment, the fibers of the spunbond nonwoven fabrichave a bicomponent structure in which the core and sheath both comprisea PLA polymer, and the sheath includes the alkane sulfonate/secondaryalkane sulfonate that is present in an amount that is from about 0.1 to1 weight percent, based on the total weight of the sheath component, andin particular, from about 0.1 to 0.75, and more particularly from about0.2 to 0.6 weight percent, and even more particularly, from about 0.3 to0.4 weight percent, based on the total weight of the sheath component.Although, the alkane sulfonate/secondary alkane sulfonate has generallydiscussed as being present in a monocomponent fiber or the sheath of abicomponent fiber, it should be recognized that other arrangements arewithin the embodiments of the present invention. For example, the alkanesulfonate/secondary alkane sulfonate may be present in only the core andnot the sheath of a bicomponent fiber, or the alkane sulfonate/secondaryalkane sulfonate may be present in both the sheath and the core.

As the amount of the alkane sulfonate/secondary alkane sulfonate in thefibers may vary depending on the amount of the alkane sulfonate in themasterbatch polymer, the structure of the fiber (e.g., monocomponent orbicomponent), and in the case of the bicomponent, the ratio of a firstpolymer component to a second component in the fiber, the followingtables provide exemplary ranges of the alkane sulfonate in various fiberstructures and at various loadings of the alkane sulfonate in themasterbatch polymer, and at various loadings of the masterbatch in thePLA polymer

TABLE 2A Amounts of the Secondary Alkane Sulfonate (SAS) in the Sheathof a bicomponent fiber having a sheath to core weight ratio of 50:50 atvarious SAS and Master Batch (MB) loadings Amount of SAS in Amount ofSAS in Amount of SAS in Amount of SAS in Sheath at an addition Sheath atan addition Sheath at an addition of Sheath at an addition Amount of of5% MB to Sheath of 10% MB to Sheath 20% MB to Sheath of 25% MB to SheathSAS in MB polymer polymer polymer polymer (%) (%) (%) (%) (%) 0.25% 0.0125 0.025 0.050 0.0625 0.50%  0.025 0.050 0.100 0.125 0.75%  0.03750.075 0.150 0.1875 1.0% 0.050 0.100 0.200 0.250 2.0% 0.100 0.200 0.4000.500 3.0% 0.150 0.300 0.600 0.750 4.0% 0.200 0.400 0.800 1.000 4.95% 0.2475 0.495 0.9904 1.2375 5.0% 0.250 0.500 1.00 1.2500 7.5% 0.375 0.7501.500 1.8750 10.0%  0.500 1.000 2.000 2.5000

TABLE 2B Amounts of the Secondary Alkane Sulfonate (SAS) in the Fabriccomprised of bicomponent fibers having a sheath to core weight ratio of50:50 at various SAS and Master Batch (MB) loadings Amount of SAS inAmount of SAS in Amount of SAS in Amount of SAS in Fabric at an additionFabric at an addition of Fabric at an addition of Fabric at an additionAmount of of 5% MB to Sheath 10% MB to Sheath 20% MB to Sheath of 25% MBto Sheath SAS in MB polymer polymer polymer polymer (%) (%) (%) (%) (%)0.25%  0.00625 0.0125 0.025 0.03125 0.50%  0.01250 0.025 0.050 0.062500.75%  0.01875 0.0375 0.075 0.09375 1.0% 0.02500 0.050 0.100 0.125002.0% 0.05000 0.100 0.200 0.25000 3.0% 0.07500 0.150 0.300 0.37600 4.0%0.10000 0.200 0.400 0.50000 4.95%  0.12375 0.2475 0.495 0.61875 5.0%0.12500 0.250 0.500 0.62500 7.5% 0.18750 0.375 0.750 0.93750 10.0% 0.25000 0.500 1.000 1.25000

TABLE 3A Amounts of the Secondary Alkane Sulfonate (SAS) in Sheath of abicomponent fiber having a sheath to core weight ratio of 30:70 atvarious SAS and Master Batch (MB) loadings Amount of SAS in Amount ofSAS in Amount of SAS in Amount of SAS in Sheath at an addition Sheath atan addition of Sheath at an addition of Sheath at an addition Amount ofof 5% MB to Sheath 10% MB to Sheath 20% MB to Sheath of 25% MB to SheathSAS in MB polymer polymer polymer polymer (%) (%) (%) (%) (%) 0.25% 0.0125 0.025 0.050 0.0625 0.50%  0.025 0.050 0.100 0.125 0.75%  0.03750.075 0.150 0.1875 1.0% 0.050 0.100 0.200 0.250 2.0% 0.100 0.200 0.4000.500 3.0% 0.150 0.300 0.600 0.750 4.0% 0.200 0.400 0.800 1.000 4.95% 0.2475 0.495 0.9904 1.2375 5.0% 0.250 0.500 1.00 1.2500 7.5% 0.375 0.7501.500 1.8750 10.0%  0.500 1.000 2.000 2.5000

TABLE 3B Amounts of the Secondary Alkane Sulfonate (SAS) in a Fabriccomprising bicomponent fibers having a sheath to core weight ratio of30:70 at various SAS and Master Batch (MB) loadings Amount of SAS inAmount of SAS in Amount of SAS in Amount of SAS in Fabric at an additionFabric at an addition of Fabric at an addition of Fabric at an additionAmount of of 5% MB to Sheath 10% MB to Sheath 20% MB to Sheath of 25% MBto Sheath SAS in MB polymer polymer polymer polymer (%) (%) (%) (%) (%)0.25%  0.0375 0.0750 0.1500 0.01875 0.50%  0.0750 0.1500 0.3000 0.03750.75%  0.01125 0.0225 0.4500 0.05625 1.0% 0.0150 0.0300 0.0600 0.07502.0% 0.0333 0.0667 0.1200 0.1500 3.0% 0.0450 0.0900 0.1800 0.2250 4.0%0.0600 0.1200 0.2400 0.3000 4.95%  0.07425 0.1485 0.2970 0.37125 5.0%0.0750 0.1500 0.3000 0.375 7.5% 0.1125 0.2250 0.4500 0.5625 10.0% 0.1500 0.3000 0.6000 0.7500

TABLE 4 Amounts of the Secondary Alkane Sulfonate (SAS) in a Fabriccomprising PLA monocomponent fibers at various SAS and Master Batch (MB)loadings Amount of SAS in Amount of SAS in Amount of SAS in Amount ofSAS in Fabric at an addition Fabric at an addition of Fabric at anaddition Fabric at an addition Amount of of 5% MB to Sheath 10% MB toSheath of 20% MB to Sheath of 25% MB to Sheath SAS in MB polymer polymerpolymer polymer (%) (%) (%) (%) (%) 0.25%  0.0125 0.025 0.050 0.06250.50%  0.025 0.050 0.100 0.125 0.75%  0.0375 0.075 0.150 0.1875 1.0%0.050 0.100 0.200 0.250 2.0% 0.100 0.200 0.400 0.500 3.0% 0.150 0.3000.600 0.750 4.0% 0.200 0.400 0.800 1.000 4.95%  0.2475 0.495 0.99041.2375 5.0% 0.250 0.500 1.600 1.25 7.5% 0.375 0.750 1.500 1.875 10.0% 0.500 1.000 2.000 2.500

Advantageously, addition of the alkane sulfonate/secondary alkanesulfonate in the PLA resin provides significant increases in mechanicalproperties in comparison to an identical or similarly prepared spunbondnonwoven fabric that does not include the alkane sulfonate/secondaryalkane sulfonate. In this regard, spunbond nonwoven fabrics comprising ablend of a PLA resin and a alkane sulfonate/secondary alkane sulfonatemay exhibit tensile strengths that are 50% greater in comparison to asimilarly prepared nonwoven fabric that does not include the alkanesulfonate/secondary alkane sulfonate. In some embodiments, the nonwovenfabric may exhibit a tensile strength that is from 50% to 200% greaterthan the tensile strength of a similarly prepared nonwoven fabric thatdoes not include the alkane sulfonate/secondary alkane sulfonate.

In particular, spunbond nonwoven fabrics comprising a blend of a PLAresin and a alkane sulfonate/secondary alkane sulfonate may exhibitincreases in machine direction (MD) tensile strengths that are fromabout 55 to 125% in comparison to a similarly prepared nonwoven fabricthat does not include the alkane sulfonate/secondary alkane sulfonate.In some embodiments, such fabrics may exhibit an increase in MD tensilestrength ranging from about 50 to 150%, such as from about 55 to 125%,from about 65 to 110%, from about 85 to 110%, or from about 90 to 110%,in comparison to a similarly prepared nonwoven fabric that does notinclude the alkane sulfonate/secondary alkane sulfonate.

In some embodiments, spunbond nonwoven fabrics comprising a blend of aPLA resin and a alkane sulfonate may exhibit increases in crossdirection (CD) tensile strengths that are from about 50 to 200% incomparison to a similarly prepared nonwoven fabric that does not includethe alkane sulfonate/secondary alkane sulfonate. In some embodiments,the fabrics may exhibit an increase in CD tensile strength ranging fromabout 50 to 170%, such as from about 55 to 165%, from about 65 to 160%,from about 85 to 150%, or from about 90 to 125%, in comparison to asimilarly prepared nonwoven fabric that does not include the alkanesulfonate/secondary alkane sulfonate.

Spunbond nonwoven fabrics comprising a blend of a PLA resin and a alkanesulfonate/secondary alkane sulfonate also exhibit increased toughness incomparison to a similarly prepared nonwoven fabric that does not includethe alkane sulfonate/secondary alkane sulfonate. The toughness ofnonwoven fabrics may be compared by examining the product resulting fromthe multiplication of the observed percent elongation and the observedtensile strength of the fabric. The product of this multiplication isreferred to as the Index of Toughness, which is approximatelyproportional to the area under the stress strain curve. As discussedbelow in the Test Methods section, all tensile and elongation values areobtained according to German Method 10 DIN 53857 in which a samplehaving a width of 5 cm and a 100 mm gauge length at a cross-head speedof 200 mm/min were recorded at peak. Since Index of Toughness resultsfrom the product of multiplying Tensile X % Elongation, the Index ofToughness has units of (N/5 cm)-%. Since all mechanical propertiesresult from testing a 5 cm wide sample, the units for Index of Toughnessin this document will be simplified to N-%.

Spunbond nonwoven fabrics comprising a blend of a PLA resin and a alkanesulfonate/secondary alkane sulfonate may exhibit an MD Index ofToughness that is from about 2,000 to 7,500 N-%, and in particular, fromabout 2,300 to 6,500, and more particularly, from about 2,300 to 6,000N-%, and a CD Index of Toughness that is from about 1,000 to 5,000 N-%,and in particular, from about 1,250 to 5,000, and more particularly,from about 1,250 to 3,500 N-%.

In one embodiment, the spunbond nonwoven fabric comprising a blend of aPLA resin and an alkane sulfonate/secondary alkane sulfonate may exhibitan increase in MD Index of Toughness that is from 20 to 1,250% incomparison to a similarly prepared nonwoven fabric that does not includethe alkane sulfonate/secondary alkane sulfonate. For example, thespunbond nonwoven fabric may exhibit an increase in MD Index ofToughness of any one or more of at least 25%, at least 100%, at least200%, at least 300%, at least 400%, at least 500%, at least 600%, atleast 700%, at least 800%, at least 900%, at least 1,000%, at least1,050%, at least 1,100%, at least 1,150%, at least 1,200%, at least1,250%, at least 1,300%, or at least 1,500%, in comparison to asimilarly prepared nonwoven fabric that does not include the alkanesulfonate/secondary alkane sulfonate.

In some embodiments, the spunbond nonwoven fabrics comprising a blend ofa PLA resin and an alkane sulfonate/secondary alkane sulfonate mayexhibit an increase in CD Index of Toughness that is from about 50 to1,000% in comparison to a similarly prepared nonwoven fabric that doesnot include the secondary alkane sulfonate. For example, spunbondnonwoven fabrics comprising a blend of a PLA resin and an alkanesulfonate/secondary alkane sulfonate may exhibit an increase in CD Indexof Toughness of any one or more of at least 60%, at least 75%, at least80%, at least 85%, at least 90%, at least 100%, at least 150%, at least200%, at least 250%, at least 300%, at least 350%, at least 400%, atleast 500%, at least 550%, at least 600%, at least 700%, at least 800%,at least 900%, at least 1,000%, or at least 1,025%, in comparison to asimilarly prepared nonwoven fabric that does not include the alkanesulfonate/secondary alkane sulfonate.

To account for variations in basis weights, it may also be useful toconsider Relative Index of Toughness for the spunbond nonwoven fabricscomprising a blend of a PLA resin and a alkane sulfonate/secondaryalkane sulfonate in comparison to similarly prepared nonwoven fabricsthat do not include the alkane sulfonate/secondary alkane sulfonate. Thespunbond nonwoven fabrics comprising a blend of a PLA resin and analkane sulfonate/secondary alkane sulfonate also exhibited significantincreases in toughness in comparison to the nonwoven fabrics of thecomparative examples. The Relative Index of Toughness is calculated fromthe Index of Toughness, which is then normalized for basis weight. TheToughness Index can be divided by basis weight to provide a normalizedIndex of Toughness with units of N-%/g/m².

Spunbond nonwoven fabrics comprising a blend of a PLA resin and analkane sulfonate/secondary alkane sulfonate may exhibit an MD RelativeIndex of Toughness that is from about 50 to 150 N-%/g/m², and inparticular, from about 75 to 125, and more particularly, from about 85to 115 N-%/g/m², and a CD Relative Index of Toughness that is from about40 to 100 N-%/g/m², and in particular, from about 45 to 85, and moreparticularly, from about 45 to 75 N-%/g/m².

In one embodiment, the spunbond nonwoven fabrics comprising a blend of aPLA resin and an alkane sulfonate/secondary alkane sulfonate may exhibitan increase in MD Relative Index of Toughness that is from 100 to 1000%in comparison to a similarly prepared nonwoven fabric that does notinclude the alkane sulfonate/secondary alkane sulfonate. In a preferredembodiment, the inventive nonwoven fabric may exhibit an increase in MDRelative Index of Toughness that is from about 80 to 500%, and morepreferably, from about 140 to 480% in comparison to a similarly preparednonwoven fabric that does not include the alkane sulfonate/secondaryalkane sulfonate. For example, the inventive nonwoven fabric may exhibitan increase in MD Relative Index of Toughness of any one or more of atleast 100%, at least 125%, at least 150%, at least 175%, at least 200%,at least 225%, at least 250%, at least 275%, at least 300%, at least325%, at least 350%, at least 375%, at least 400%, at least 425%, atleast 450%, at least 475%, at least 500%, at least 525%, at least 550%,at least 575%, at least 600%, at least 625%, at least 650%, at 675%, atleast 700%, at least 725%, at least 750%, at least 775%, at least 800%,at least 825%, at least 850%, at least 875%, at least 900%, at least925%, at least 950, at least 975%, or at least 1,000%, in comparison toa similarly prepared nonwoven fabric that does not include the alkanesulfonate/secondary alkane sulfonate.

In one embodiment, the spunbond nonwoven fabric may exhibit an increasein CD Relative Index of Toughness that is from 100 to 1000% incomparison to a similarly prepared nonwoven fabric that does not includethe alkane sulfonate/secondary alkane sulfonate. In a preferredembodiment, the spunbond nonwoven fabrics comprising a blend of a PLAresin and a secondary alkane sulfonate may exhibit an increase in CDRelative Index of Toughness that is from about 140 to 500%, and morepreferably, from about 140 to 410% in comparison to a similarly preparednonwoven fabric that does not include the alkane sulfonate/secondaryalkane sulfonate. For example, the spunbond nonwoven fabric may exhibitan increase in MD Relative Index of Toughness of any one or more of atleast 100%, at least 125%, at least 150%, at least 175%, at least 200%,at least 225%, at least 250%, at least 275%, at least 300%, at least325%, at least 350%, at least 375%, at least 400%, at least 425%, atleast 450%, at least 475%, at least 500%, at least 525%, at least 550%,at least 575%, at least 600%, at least 625%, at least 650%, at 675%, atleast 700%, at least 725%, at least 750%, at least 775%, at least 800%,at least 825%, at least 850%, at least 875%, at least 900%, at least925%, at least 950, at least 975%, or at least 1,000%, in comparison toa similarly prepared nonwoven fabric that does not include the alkanesulfonate/secondary alkane sulfonate.

When comparing properties of different nonwovens it is often useful tocompare the root mean square of the combined values of the MD and CDproperty of interest. This method allows comparison of single values.The root mean square provides a single number that combines input fromboth the MD and the CD values by taking the square root of the sum ofthe square of the MD value plus the square of the CD value. Use of theroot mean square method to combine the MD and the CD results isparticularly useful if samples to be compared were made on differentmachines or under some different condition that might influence theMD/CD ratio. The root mean square of the Toughness Index per basisweight is calculated with the following formula:

$\left( {{\sqrt{\frac{({MDTI})^{2} + ({CDTI})^{2}}{2}}/{Basis}}\mspace{14mu} {weight}} \right.$

Where MDTI is the machine direction Toughness Index and CDTI is thecross direction Toughness Index.

Spunbond nonwoven fabrics comprising a blend of a PLA resin and analkane sulfonate/secondary alkane sulfonate may have a root mean squareof the Toughness Index per basis weight that is at least 55 N-%/g/m²,and more preferably, at least 65 N-%/g/m², and even more preferably atleast 70 N-%/g/m². In one embodiment, the spunbond nonwoven fabric has aroot mean square of the Toughness Index per basis weight has a valuefrom about 55 to 250 N-%/g/m², and in particular, from about 65 to 150N-%/g/m², and more particularly, from about 65 to 100 N-%/g/m². In oneembodiment, the spunbond nonwoven fabric has a root mean square of theToughness Index per basis weight of at least 75, at least 80, at least85, at least 90, at least 95, at least 100, at least 105, at least 110,at least 115, at least, 120, at least 125, at least, 130, at least 135,at least 140, at least 145, at least 150, at least 155, at least 160, atleast 165, at least 170, at least 175, at least 180, at least 185, atleast 190, at least 195, and at least 200 N-%/g/m².

By “similarly prepared nonwoven fabric” it should be understood thecomparison nonwoven fabric has the identical polymer composition withthe exception of the secondary alkane sulfonate, and that slightvariations in processing conditions, such as temperature (e.g.,extruder, calendaring, and die temperatures), draw speeds, and pressuresmay exist.

IV. Process of Making the Cleaning Wipe

Cleaning wipes in accordance with the invention may be prepared in awide variety of ways. In one embodiment, the wipe may be prepared in aone-step continuous in-line process in which the fibrous layer is firstformed by depositing a plurality of continuous filaments onto acollection surface to form a web, which is then followed by depositing aplurality of meltblown fibers onto the surface of the previously formedweb to form a composite web having an abrasive layer and a fibrouslayer. Thereafter, the composite web may be subjected to a bonding step.The resulting composite web may then be processed to form individualcleaning wipes.

Alternatively, the cleaning wipe may be prepared in a two-step processin which a fibrous layer is separately made in a first step, and then ina second step meltblown fibers are deposited on the surface of thefibrous layer to form a meltblown web defining the abrasive layer. Asdiscussed below, the meltblown fibers are generally deposited onto thefibrous layer in a molten or semi-molten state which then allows them tobond to the fibers of the fibrous layer as they cool and solidify.

In a preferred embodiment, the fibrous layer comprises a spunbondnonwoven fabric comprising filaments having a high sustainable polymercontent, such a PLA resin. For example, in embodiments in which thesustainable polymer component comprises PLA, the process may includeproviding a stream of molten or semi-molten PLA resin, forming aplurality of drawn PLA continuous filaments, depositing the plurality ofPLA continuous filaments onto a collection surface, exposing theplurality of PLA continuous filaments to ions, and bonding the pluralityof PLA continuous filaments to form the PLA spunbond nonwoven fabric.According to certain embodiments, for example, forming the plurality ofPLA continuous filaments may comprise spinning the plurality of PLAcontinuous filaments, drawing the plurality of PLA continuous filaments,and randomizing the plurality of PLA continuous filaments.

In this regard, the spunbond nonwoven fabric may be produced, forexample, by the conventional spunbond process on spunbond machinery suchas, for example, the Reicofil-3 line or Reicofil-4 line fromReifenhauser, as described in U.S. Pat. No. 5,814,349 to Geus et al, theentire contents of which are incorporated herein by reference, whereinmolten polymer is extruded into continuous filaments which aresubsequently quenched, attenuated pneumatically by a high velocityfluid, and collected in random arrangement on a collecting surface. Insome embodiments, the continuous filaments are collected with the aid ofa vacuum source positioned below the collection surface. After filamentcollection, any thermal, chemical or mechanical (e.g., needling orhydroentanglement) bonding treatment may be used to form a bonded websuch that a coherent web structure results. As one skilled in the artwill understand, examples of thermal bonding may include thru-airbonding where hot air is forced through the web to soften the polymer onthe outside of certain fibers in the web followed by at least limitedcompression of the web or calender bonding where the web is compressedbetween two rolls, at least one of which is heated, and typically one isan embossed roll. In a preferred embodiment, bonding of the web occursfollowing the step of depositing the meltblown fibers onto the surfaceof the spunbond nonwoven fabric.

With reference to FIG. 2, for example, a schematic diagram of a systemfor preparing the cleaning wipe that is in accordance with certainembodiments of the invention is illustrated and designated by referencecharacter 30.

As shown in FIG. 2, a sustainable polymer resin source (i.e., a hopper)32 is in fluid communication with a spunbond spin beam 34 via anextruder 36. The sustainable polymer resin is heated in the extruder 36to provide a molten or semi-molten polymer stream that is introducedinto a spunbond spin beam 34. It should be noted that a secondary alkanesulfonate may optionally be introduced directly into the extruder or maybe introduced into the sustainable polymer resin source (e.g., thehopper) prior to the sustainable polymer resin being introduced into theextruder.

Although FIG. 2 illustrates an embodiment having two sustainable polymerresin sources 32 and two extruders 36, the system may include any numberof polymer sources (e.g., PLA, synthetic polymer, such as polypropylene,polyethylene, etc.) and extruders as dictated by a particularapplication as understood by one of ordinary skill in the art. Followingextrusion, the extruded polymer may then enter a plurality of spinnerets(not shown) for spinning into filaments. Following spinning, the spunfilaments may then be drawn (i.e. attenuated) via a drawing unit (notshown) and randomized in a diffuser. The spin beam 34 produces a curtainof filaments that is deposited on the collection surface 40 at point 38.

In some embodiments, for instance, the collection surface may compriseconductive fibers. The conductive fibers may comprise monofilament wiresmade from polyethersulfone conditioned with polyamide (e.g., Huycon-LX135). In the machine direction, the fibers comprise polyamideconditioned polyethersulfone. In the cross-machine direction, the fiberscomprise polyamide conditioned polyethersulfone in combination withadditional polyethersulfone. Examples of suitable collection surfacesare available from Albany, Nipon, AstenJohnson, and Xerium.

In some embodiments, a pair of cooperating rolls 42 (also referred toherein as a “press roll”) stabilize the web of the continuous filamentsby compressing the web before delivery to the calender 50 for bonding.In some embodiments, for example, the press roll may include a ceramiccoating deposited on a surface thereof. In certain embodiments, forinstance, one roll of the pair of cooperating rolls 42 may be positionedabove the collection surface 40, and a second roll of the pair ofcooperating rolls 42 may be positioned below the collection surface 40.

A meltblown spin beam 44 is positioned downstream of the spunbond spinbeam and is configured to deposit a layer of meltblown fibers onto thesurface of the spunbond nonwoven fabric. A sustainable polymer resinsource (i.e. hopper) 46 is in fluid communication with the meltblownspin beam 44 via the extruder 48. As discussed above, the meltblownprocess conditions are selected so as to provide a meltblown web havinga desired abrasiveness depending on the intended application of theresulting cleaning wipe. For example, a cleaning wipe having anincreased coarseness may be produced by selecting meltblown processconditions that result in a higher degree abrasive structures beingformed on the meltblown web, for example, of shot being produced and/ora higher degree of conglomeration of adjacent meltblown fibers.

Upon deposition of the meltblown fibers onto surface of the spunbondnonwoven fabric, the “hot” meltblown fibers will still be in a molten orsemi-molten state, which facilitates bonding (e.g, “self-bonding”) ofthe meltblown fibers to each other and to the fibers of the spundbondnonwoven fabric to form a composite web. The resulting bonds provideintegrity and strength to the resulting composite web.

In addition the composite web of meltblown and spunbond fibers may befurther strengthened by calender bonding the structure together. Forexample in FIG. 2 the system 30 includes a calender roll 50 comprising acooperating smooth roll and embossed roll. Significant care must be usedin such a calender bonding operation to select the bonding pattern, thebonding temperatures of the two rolls, the bonding pressure for the pairof rolls and proper static control for the composite web to achieve thedesired structural integrative of the composite web, while preservingthe open, abrasive surface of the meltblown web, and managing thenatural propensity for the meltblown web surface to wrap the calenderroll/rolls. To further prevent roll wrapping the coated roll surface maybe treated with an anti-stick release coating as taught in EuropeanPatent No 1,432,860.

Following bonding, the composite web may then be moved to a winder 62,where the composite web is wound onto rolls. The composite web may thenbe further processed to prepare cleaning wipes in accordance withembodiments of the invention.

During the course of their investigation, the inventors have discoveredthat static generation during fiber spinning and web processing when asustainable polymer, such as PLA, is exposed on the fiber surfacepromotes web wraps at the press rolls and calender of the spunbondsystem. This web wrap is undesirable and generally has prevented thehigh speed production of fabrics comprising a high content ofsustainable polymer (e.g., PLA), or fabrics in which the sustainablepolymer is exposed at the surface of the fibers. One method ofaddressing web wrap is by increasing the humidity of the spunbondprocess by, for example, injecting steam into the air stream used toquench the just-spun fibers or providing a fine mist or fog of moisturearound the press rolls where the spun fibers are first formed into anunbonded web. Although the extra humidity provides some protection fromweb wraps, the addition of high moisture over a period of time maypromote corrosion of the spunbond equipment and growth of mold ormicroorganisms detrimental to nonwoven use in hygiene and medicaloperations.

To address the issue of static generation, the process may furthercomprise dissipating static charge from the spunbond nonwoven fabricproximate to one or more of the collection surface, press rolls,calender roll, or the like via a static control unit. In someembodiments, for example, the static control unit may comprise anionization source. In further embodiments, for instance, the ionizationsource may comprise an ionization bar. However, in other embodiments,for example, dissipating static charge from the spunbond nonwoven fabricmay comprise contacting the spunbond nonwoven fabric with a static bar.

Advantageously, the inventors have discovered that fabrics comprisinghigh sustainable polymer content, such as a high PLA content, may beprepared at commercially viable processing speeds by positioning one ormore ionization sources in close proximity to the spunbond nonwovenfabric. For example, in one embodiment, an ionization source 52 may bepositioned near the spin beam 34 and the winder 62 to activelydissipate/neutralize static charge without contacting the fabric. Asexplained below, the ionization source exposes the spunbond nonwovenfabric to a stream of ions, which act to neutralize static charges inthe nonwoven fabric. The stream of ions may include positive ions,negative ions, and combinations thereof.

In some embodiments, it may also be desirable to position a staticcontrol unit 54 downstream of the outlet of the meltblown spin beam 44.In the illustrated embodiment, the static control unit is depicted asbeing positioned near the calender 50. The static control unit 54 may bepassive static bar requiring contact with the fabric or an activeionization bar, which does not require contact with the fabric. Finally,an optional humidity unit 60 may be used in conjunction with the spinbeam 34 and/or the press roll 42 to reduce static via added moisture.

In accordance with certain embodiments, for example, the firstionization source may be positioned above the collection surface anddownstream of a point at where the continuous filaments are deposited onthe collection surface. However, in other embodiments, for instance, thefirst ionization source may be positioned between the outlet of the spinbeam and the collection surface.

As discussed previously, the system may further comprise a press rollpositioned downstream from the outlet of the spin beam. In this regard,the press roll may be configured to stabilize the web of the continuousfilaments by compressing said web before delivery of the continuousfibers from the outlet of the spin beam towards the calender. In thoseembodiments including the press roll, for example, the first ionizationsource may be positioned downstream from the press roll. In otherembodiments, for instance, the first ionization source may be positionedbetween the spin beam and the press roll.

In some embodiments and as shown in FIG. 3, the system may comprise avacuum source 58 disposed below the collection surface for pulling theplurality of continuous filaments from the outlet of the spin beam ontothe collection surface before delivery to the calender.

FIGS. 3A-3C, for example, are schematic diagrams illustratingpositioning of the first ionization source in accordance with certainembodiments of the invention. As shown in FIG. 3A, the first ionizationsource 52 is positioned downstream of the outlet (i.e. diffuser) 64 ofthe spin beam 4 but upstream of the press roll 42. In FIG. 4B, however,the first ionization source 52 is positioned downstream of the pressroll 42. In FIG. 2C, the first ionization source is positioneddownstream of the point 38 at which the curtain of filaments 66 aredeposited on the collection surface but also within the outlet of thediffuser.

Preferably, the ionization source comprises a device that is capable ofactively discharging ions with the use of electrodes, ionizing airnozzles, ionizing air blowers, and the like. In one embodiment, theionization source comprises an active discharge ionization bar thatactively discharges ions in the direction of the nonwoven fabric.Examples of suitable ionization bars may include ElektrostatikDischarging Electrode E3412, which is available from Iontis.

In one embodiment, the ionization bar may extend over the web in thecross direction. Preferably, the ionization bar extends in the crossdirection across the total width of the nonwoven fabric. In furtherembodiments, the ionization bar may extend under the web and thecollection surface in the cross direction. However, positioning theionization bar under the collection surface may be less effective thanpositioning the ionization bar over the web in the cross direction.

According to certain embodiments, for example, the first ionizationsource and the collection surface may be separated by a distance fromabout 1 inch to about 24 inches. In other embodiments, for instance, thefirst ionization source and the collection surface may be separated by adistance from about 1 inch to about 12 inches. In further embodiments,for example, the first ionization source and the collection surface maybe separated by a distance from about 1 inch to about 5 inches. As such,in certain embodiments, the first ionization source and the collectionsurface may be separated by a distance from at least about any of thefollowing: 1, 1.25, 1.5, 1.75, and 2 inches and/or at most about 24, 20,16, 12, 10, 9, 8, 7, 6, and 5 inches (e.g., about 1.5-10 inches, about2-8 inches, etc.).

In accordance with certain embodiments, for instance, the system mayfurther comprise a static control unit positioned and arranged todissipate static from the spunbond nonwoven fabric proximate to thecalender. In some embodiments, for example, the static control unit maybe positioned upstream from, and adjacent to, the calender. In otherembodiments, however, the static control unit may be positioneddownstream from, and adjacent to, the calender.

In some embodiments, for instance, the static control unit may comprisea passive static bar. In such embodiments, the static control unit maycontact the spunbond nonwoven fabric in order to dissipate staticcharge. In other embodiments, however, the static control unit maycomprise a second ionization source. As such, the second ionizationsource may actively dissipate static charge from the spunbond nonwovenfabric such that contact by the second ionization source with thespunbond nonwoven fabric is not required in order to dissipate thestatic charge.

In accordance with certain embodiments, for instance, the process mayfurther comprise increasing humidity while forming the plurality ofcontinuous filaments. In such embodiments, for example, increasinghumidity may comprise applying at least one of steam, fog, mist, or anycombination thereof to the plurality of continuous filaments.

According to certain embodiments, for example, the system may furthercomprise a winder 62 positioned downstream from the calender. In suchembodiments, for instance, the system may also include a thirdionization source positioned and arranged to expose the PLA spunbondnonwoven fabric to ions proximate to the winder. In some embodiments,for example, at least one of the first ionization source, the staticcontrol source (e.g., the second ionization source), and the thirdionization source may comprise an ionization bar. In this regard, forinstance, the first ionization source, the static control source, andthe third ionization source may be configured to actively dissipatestatic charge created during preparation of the PLA spunbond nonwovenfabric.

In accordance with certain embodiments, for instance, bonding of thecomposite web may comprise thermal point bonding the structure with heatand pressure via a calender having a pair of cooperating rolls includinga patterned roll. In such embodiments, for example, thermal pointbonding the structure may comprise imparting a three-dimensionalgeometric bonding pattern onto the composite web. In some embodiments,for instance, imparting the bonding pattern onto the composite web maycomprise imparting at least one of a diamond pattern, a hexagonal dotpattern, an oval-elliptic pattern, a rod-shaped pattern, or anycombination thereof.

In bonding the composite web, it is desirable to maintain abrasivestructures and any void volume (e.g., unevenness, irregularities in thesurface, and the like) within the meltblown web during the bondingprocess in order to maintain the abrasiveness of the surface.Accordingly, in some embodiments, it may be desirable to arrange thecalender such that the meltblown surface of the composite web isarranged facing the patterned roll, and the spunbond nonwoven fabricsurface is arranged facing the anvil roll. In addition, it is believedthat lightly bonding the composite web helps to retain abrasiveness ofthe meltblown web during bonding.

In certain embodiments, for example, the bonding pattern may cover fromabout 5% to about 30% of the surface area of the patterned roll. Inother embodiments, for instance, the bonding pattern may cover fromabout 10% to about 25% of the surface area of the patterned roll. Assuch, in certain embodiments, the bonding pattern may cover from atleast about any of the following: 5, 6, 7, 8, 9, and 10% and/or at mostabout 30, 29, 28, 27, 26, and 25% (e.g., about 8-27%, about 10-30%,etc.). By way of example only, the bonding pattern may comprise thediamond pattern, and the bonding pattern may cover about 10% to 25% ofthe surface area of the patterned roll. In further embodiments, forinstance, the bonding pattern may comprise the oval-elliptic pattern,and the bonding pattern may cover about 10% to 18% of the surface areaof the patterned roll. In preferred embodiments, the bonding pattern maycover from about 10% to 15% of the surface area of the patterned roll.

In some embodiments, for example, the calender may comprise a releasecoating. As understood by one of ordinary skill in the art, the nonwovenstrength resulting from calendar bonding is a complex function of the %area covered by the bond, temperature of the calender rolls, compressionpressure of the rolls against the composite structure, and the speed ofthe web through the calendar.

In some embodiments, the composite web may be “self-bonded.” Inself-bonding, the meltblown fibers are in a molten or semi-molten state.As they are deposited onto the fibrous layer, these “hot” meltblownfibers bond to each other and the fibers of the fibrous layer. In someembodiments, the composite web having the self-bonded meltblown web isnot subject to a further bonding step. In other embodiments, thecomposite web having the self-bonded meltblown web may be subjected toan additional bonding step, such as thermal calender bonding asdescribed previously.

In accordance with certain embodiments, for instance, the spunbondprocess may occur at a fiber draw speed greater than about 2500 m/min.In other embodiments, for example, the process may occur at a fiber drawspeed from about 3000 m/min to about 4000 m/min. In further embodiments,for instance, the process may occur at a fiber draw speed from about3000 m/min to about 5500 m/min. As such, in certain embodiments, theprocess may occur at a fiber draw speed from at least about any of thefollowing: 2501, 2550, 2600, 2650, 2700, 2750, 2800, 2850, 2900, 2950,and 3000 m/min and/or at most about 5500, 4000, 3950, 3900, 3850, 3800,3750, 3700, 3650, 3600, 3550, and 3500 m/min (e.g., about 2700-3800m/min, about 3000-3700 m/min, etc.).

In a preferred embodiment, the foregoing discussed system is configuredto prepare a composite web comprising a fibrous layer comprising aspunbond nonwoven fabric comprising continuous filaments having a highPLA content, and an abrasive layer comprising meltblown fibers having ahigh PLA content. Preferably, the composite web has a PLA content thatis at least 50% by weight, based on the total weight of the structure,and in particular, at least 70%, at least 75%, at least 80%, at least85%, at least 90, and at least 95%. In a particularly preferredembodiment, the composite web has a 100% PLA content.

Certain embodiments according to the invention provide systems forpreparing a cleaning wipe comprising a PLA spunbond nonwoven fabric anda PLA meltblown web. In this regard, the system may include a first PLAsource configured to provide a stream of molten or semi-molten PLAresin, a spunbond spin beam in fluid communication with the first PLAsource, a collection surface disposed below an outlet of the spin beamonto which PLA continuous filaments are deposited to form the PLAspunbond nonwoven fabric, a first ionization source positioned andarranged to expose the PLA continuous filaments to ions, a second PLAsource, a meltblown spin beam in fluid communication with the second PLAsource and configured to deposit a web of meltblown PLA fibers onto thePLA spunbond nonwoven fabric, and a calender positioned downstream ofthe first ionization source.

In accordance with certain embodiments, for example, the system mayfurther comprise a humidity unit positioned within or downstream fromthe spin beam. In such embodiments, for instance, the humidity unit maycomprise at least one of a steam unit, a fogging unit, a misting unit,or any combination thereof. In this regard, for example, humidity may beadded in the spin beam during the formation of the plurality of PLAcontinuous filaments and/or near the press roll(s) (in those embodimentsutilizing at least one press roll) in order to provide additionalmanagement of static charge that develops during the production of thePLA spunbond nonwoven fabric.

The cleaning wipes may be used in a wide variety of different cleaningapplications including cleaning, disinfecting, or treating a surfacesuch as dishes, surfaces for preparing food, cooking surfaces, thefloor, and surfaces in the bathroom. In some embodiments, it may bedesirable to use the cleaning wipe with a cleaning composition, such asliquid cleaning composition. In this regard, the cleaning wipe may beprovided in a packaged form in which the cleaning wipe is impregnatedwith a cleaning composition. In other embodiments, the cleaningcomposition may be added by the end user. Non-limiting examples offormulations that may be used with the cleaning wipes are taught byTruong et al in U.S. 2015/0373970 Antimicrobial Compositions, Wipes, andMethods as well as by Chen et al. in U.S. 2005/0136772, the contents ofboth which are hereby incorporated by reference.

The basis of the cleaning wipe may be selected based on the desired enduse of the cleaning wipe. In one embodiment, the cleaning wipe may havea basis weight ranging from about 15 grams per square meter (GSM) to 100GSM. For other applications, a preferred range may be from about 20 GSMto 80 GSM, and in still other embodiments, the cleaning wipe may have abasis weight ranging from about 30 GSM to 60 GSM. Finally in otherembodiments, a basis weight from 25 GSM to 50 GSM may be preferred.

The ratio of the meltblown layer to the spunbond layer may also dependon the final application such as a need for scrubbing, volume to hold orcontain a cleaning formulation, and ultimate wipes strength. Thus aratio of 20/80 to 40/60 meltblown web to spunbond nonwoven fabric may bepreferred when strength is of particular importance. On the other hand,if scrubbing or volume to hold a cleaning formulation is more important,a ratio of 40/60 to 60/40 meltblown web to spunbond nonwoven fabric maybe preferred.

Thus both the total basis weight and the ratio of the layer meltblownweb to the spunbond nonwoven fabric can be tailored to meet the finalneeds of the consumer.

EXAMPLES

The following examples are provided for illustrating one or moreembodiments of the present invention and should not be construed aslimiting the invention.

The fabrics in the following examples were prepared on a line equippedwith a Reifenhaeuser Reicofil-3 spunbond spin beam, an Accuweb meltblownspin beam, and a Reifenhaeuser Reicofil-4 spunbond spin beam. Each ofthe examples were prepared using the setup described in Example 1 unlessotherwise indicated. Moreover, unless otherwise indicated allpercentages are weight percentages. The materials used in the examplesare identified below.

Test Methods

Titer was calculated from microscopic measurement of fiber diameter andknown polymer density per German textile method C-1570.

Basis Weight was determined generally following the German textilemethod CM-130 from the weight of 10 layers of fabric cut into 10×10 cmsquares.

Tensile was determined in accordance with Method 10 DIN 53857 using asample with 5 cm width, 100 mm gauge length, and cross-head speed of 200mm/min. Tensile strengths were measured at peak.

Elongation was determined in accordance with Method 10 DIN 53857 using asample with 5 cm width, 100 mm gauge length, and cross-head speed of 200mm/min. Elongations were measured at peak.

Fabric Shrinkage was determined by cutting three samples taken acrossthe web width of nominal dimensions of MD of 29.7 cm and CD of 21.0 cm;measuring the actual MD and CD width at three locations in the sheet;placing the sample in water heated to 60 C for 1 minute; and remeasuringthe MD and CD dimensions at the above three locations. The average widthmeasurement after exposure divided by the original measurement×100%yielded the % Shrinkage. A low % shrinkage value suggests that thecontinuous fibers comprising PLA have been spun and drawn at sufficientspeed to yield after bonding a high strength stable fabric.

Kinetic Coefficient of Friction was measured according to Method C-1231Coefficient of Friction. In this method the force is measured to move asled whose base is covered by fabric with fiber side of interestdownward against the specified surface. Testing details include Loadcell at 100N, Clamps Distance at 138.5 mm and Crosshead Speed=200mm/minute. The results below in Table XYZ are the average of the resultsfrom three tests.

Bending Length was measured according to Test C-1381 Bending Length withSample Width at 25.0 mm, Sample Length at 250.0 mm, and waitingtime=8+/−2 seconds. In this test a specified fabric samples is movedhorizontally until the tip of the fabric bends downward to contact aspecified surface. Soft drapeable fabrics show a low Bending Lengthwhile stiff fabrics resist bending so have a high Bending Length.

Handle-O-Meter Stiffness was measured according to CM-490Handle-O-Meter. This test measures the force needed to force thespecified nonwoven web thought a slot. Thus H-O-M provides a value thatcombines frictional and bending properties.

In the following examples, the cleaning wipes were prepared in atwo-step process in which a spunbond nonwoven fabric comprising 100% PLAfibers was made and then calender bonded. In a second step, 100% PLAmeltblown fibers were deposited onto the surface of the spunbondnonwoven fabric.

The spunbond nonwoven fabric was comprised of 100% PLA bicomponentfibers prepared on a pilot line equipped with a Reicofil-4 spinningbeam. A press roll (R-4 press roll) was positioned on the collectionsurface downstream of where the filaments are deposited on thecollection surface. An Ionis Elektrostatik Discharging Electrode E3412(i.e. ionization bar) was positioned above and extending over thecollection surface in the cross direction and placed approximately 1 to3 inches above the collection surface and 2 to 3 inches downstream ofthe R-4 press roll.

The spunbond nonwoven fabric was comprised of bicomponent 30/70NatureWorks Grade 6752/NatureWorks Grade 6202/sheath/core fibers madewith ionization bars positioned as discussed above to minimize static.The fabric was produced at spin beam temperatures of 235° C. at theextruder and 240° C. at the die. The spunbond fabric was produced usinga fiber draw speed of 3,800 m/min and a line speed of 90 m/min. Thecalender used for bonding the spunbond fabric had a calender temperatureof 160° C. for the pattern roll and 147° C. for the anvil roll and acalender pressure of 40 N/mm. The properties of the spunbond nonwovenfabric are summarized in the table below.

TABLE 5 Properties of PLA Spunbond Fabric Basis MD MD Tensile per CD CDTensile per MD % CD % MD Toughness CD Toughness Titer Weight TensileBasis Weight Tensile Basis Weight Elong. Elong. Index Index UnitsExample DTEX g/m² N/5 cm N-m²/g-5 cm N/5 cm N-m²/g-5 cm % % N-% N-% PLA1.7 39.8 70.7 1.78 26.6 0.668 14.7 28.61 1881 761 Spunbond *Calculatedbasis weight for sample

TABLE 6 Shrinkage Resistance for PLA Spunbond Fabric Shrink ShrinkExample (MD) % (CD)% Area Shrink % PLA Spunbond 3.1 −1.4 1.8 Example

In a next step, a web of 100% PLA meltblown fibers (NatureWorks Grade6252 D PLA resin) were deposited onto the previously prepared PLAspunbond nonwoven fabric to produce a composite web. Bonding between themeltblown fibers and the spunbond nonwoven fabric occurred as themeltblown fibers cooled and solidified. The composite web of Samples1-10 were not subject to a further bonding step, such as calenderbonding. The meltblowing process was operated with extruder temperatureat 250° C., an Adapter Zone temperature at 250° C., and a temperature atthe die of 250° C. The air to the meltblown process was supplied at 270°C. and maintained between approximately 242-252° C. with hot air volumemaintained 520 m³/hour. Table 7, below, process key process conditionsmaintained during production of selected finished wipes. Basis weight ofthe finished roll was controlled during trial production by balancingmeltblown thru-put with the speed of the spunbond web under themeltblown beam.

TABLE 7 PLA Melt Blown Process DCD Relative (relative Suction CalculatedAddition of Thru-put Process Air mm above Blower Meltblown Basis SukanoAdditive Sample No. (RPM) (m³/hr) the wire) (RPM) Weight - (GSM) S546-Q1(%) Sample 1 24 500 280 800 10.7 0.5 69-02 Sample 2 24 1000 180 120010.7 0.5 69-03 Sample 3 24 1000 180 1200 10.7 0 69-04 Sample 4 24 500280 800 10.7 0 69-05 Sample 5 24 200 360 800 10.7 0 69-06 Sample 6 20200 360 800 14.3 0 69-07 Sample 7 20 200 280 800 14.3 0 69-08 Sample 820 200 280 800 14.1 0.5 69-09 Sample 9 20 200 360 800 14.3 0.5 69-10Sample 10 No Data No Data No Data No Data No Data No Data 69-11

The composite structures of Samples 1-10 were then evaluated forabrasiveness, softness, and drapeability. The results are summarized inTables 8-11 below.

TABLE 8 Abrasiveness as a function of the kinetic coefficient offriction Coefficient of Friction MD Coefficient of FrictionDirection(1)(2) Meltblown Coefficient of Friction MD MD Direction(1)Sample Side against Meltblown Direction(1) Meltblown Side Spunbond Sideagainst Number Side(3) against Smooth Steel(4) Smooth Steel(5) Sample 10.77 0.06 0.03 69-02 Sample 2 0.32 0.05 0.02 69-03 Sample 3 0.30 0.060.03 69-04 Sample 4 0.63 0.05 0.02 69-05 Sample 5 0.86 0.05 0.03 69-06Sample 6 0.80 0.06 0.03 69-07 Sample 7 0.45 0.06 0.02 69-08 Sample 80.54 0.05 0.03 69-09 Sample 9 1.04 0.05 0.04 69-10 Sample 10 0.60 0.050.04 69-11 (1)Coefficient of Friction measured according to MethodC-1231 Coefficient of Friction. Average of three tests. Load cell = 100N, Clamps Distance = 138.5 mm; Crosshead Speed = 200 mm/minute,(2)Typical Coefficient of Variance for the Coefficient of Friction wasapproximately 10%. (3)Bottom of sled covered with experimental wipe withmeltblown side facing down against a surface covered by a second layerof the wipe with meltblown surface of the wipe facing up. (4)Bottom ofsled covered with experimental wipe with meltblown side facing downagainst a surface of smooth steel. (5)Bottom of sled covered withexperimental wipe with spunbond side facing down against a surface ofsmooth steel.

In Table 8, above, the abrasiveness of each of the Samples 1-10 wereevaluated based on the kinetic coefficient of friction for each of thesamples. A high value suggests a rough surface better able for exampleto remove dried food or paint accidentally contaminating areas outsidethe target area to paint. A low value would suggest mild abrasion such aneeded for examples to cleaning a polished wooded surface where dustmust be removed without risk of scratching the surface. As can be seenin the two far right columns, conducting the test against the surface ofthe sled (procedures (4) and (5)) provided (procedures (4) and (5))little differentiation between the samples in the measured coefficientof friction. However, when procedure (3) was employed (meltblown surfaceagainst the identical meltblown surface) a difference in the kineticcoefficient of friction for each sample was observed. Samples 2, 3, and7 all exhibited a kinetic coefficient of friction of less than 0.49, andtherefore provided an abrasiveness that would be consider fine. Samples1, 4, 8, and 10 exhibited a kinetic coefficient of friction between 0.5and 0.79, and would therefore be considered a medium abrasive cleaningwipe. Samples 5 and 6 exhibited a kinetic coefficient of frictionbetween 0.8 and 0.99, and would therefore be considered a courseabrasive cleaning wipe. Finally, Sample 9 exhibited a kineticcoefficient of friction greater than 1.0, and would therefore beconsidered to be a very course abrasive cleaning wipe.

In addition to measuring the kinetic coefficient of friction of thesample wipes, SEM images of the surface of select cleaning wipes werealso obtained. The following details outline the process used by ourPeine Test laboratory to make the SEM images provided in FIGS. 4A-6B.The SEM Instrument was a PERSONAL SEM 75, and utilized a DESK VSputterer (gold). 5 mm×5 mm samples were prepared and placed on a sampleholder. The holder with sample was placed into the SEM instrument andthe vacuum chamber was closed. The vacuum pump was started and once highvacuum was achieved the electron beam was turned on and optimum beamvoltage was selected. The filament was increased to 70 to 80%, and thena spot was selected and magnified. The spot was then scanned to obtainthe SEM image.

The SEM images were also used to measure the fiber diameters andcalculate DTEX of the fibers. DTEX was calculated by the followingformula where PLA density is taken as 1.24 grams/cm³.

(Diameter in micrometers/2) squared×Pi×polymer density (g/cm³)×0.01=DTEX(grams divided by 10000 meters). Fiber Diameters and DTEX are providedin Table 9 below.

In this regard, FIGS. 4A and 4B are SEM images of the surface of theabrasive layer (i.e, meltblown web) of Sample 2 taken at a magnificationof 500× and 750×, respectively. FIGS. 5A and 5B are SEM images of thesurface of the abrasive layer (i.e, meltblown web) of Sample 5 taken ata magnification of 500× and 750×, respectively. FIGS. 6A and 6B are SEMimages of the surface of the abrasive layer (i.e, meltblown web) ofSample 9 taken at a magnification of 500× and 750×, respectively.

In the SEM image of Sample 2, which corresponds to a cleaning wipehaving a surface with a fine abrasiveness, it can be seen that may ofthe meltblown fiber are conglomerated (i.e., married) to adjacent fiberto produce an uneven, abrasive surface. The uneven surface of theabrasive layer is even more pronounced in the SEM images of Samples 5and 9. In particular, the surfaces of Samples 5 and 9 have a morecomplex topography with much curling of fibers and marring of fibers.

As noted in Table 9, below Samples 5 and 9 show a significant differencein meltblown DTEX and meltblown fiber diameter in comparison to Samples2 and 3. Unless otherwise stated, the measurements in Table 9 are fromthe meltblown side of cleaning wipe.

TABLE 9 Fiber Diameter and DTEX for Meltblown and spunbond fibers inCleaning Wipes Fiber Diameter - DTEX Sample Average Fiber Diameter -DTEX Standard No. (Micrometers) Standard Deviation (grams) DeviationSample 2 8.06 2.16 0.67 0.34 Sample 3 6.52 1.84 0.44 0.23 Sample 5 12.171.89 1.60 0.45 Sample 9* 10.79 1.34 1.15 0.29 Sample 9 - 15.66 0.882.40. 0.27 Spunbond side *Although Sample 9 exhibited an average fiberdiameter of 10.79 micrometers, the average Kinetic Coefficient ofFriction was 1.04, and therefore Sample 9 was classified as “verycourse” based on the measured abrasiveness.

TABLE 10 Bending Length Bending Bending Length in Length in MD BendingLength in Bending Length in MD direction with direction with CDdirection with CD direction with Sample Meltblown Layer Up SpunbondMeltblown Layer Spunbond Layer Up Number (cm) Layer Up (cm) Up (cm) (cm)Sample 1 5.5 6.2 3.7 3.9 69-02 Sample 2 5.5 6.2 4.2 4.3 69-03 Sample 35.9 6.0 3.7 4.0 69-04 Sample 4 5.5 6.3 4.2 4.3 69-05 Sample 5 5.2 5.44.2 4.6 69-06 Sample 6 5.4 6.2 3.9 4.1 69-07 Sample 7 5.3 5.8 4.1 4.569-08 Sample 8 6.0 6.6 4.0 4.4 69-09 Sample 9 5.3 6.0 4.1 3.9 69-10Sample 10 5.4 7.0 4.4 4.2 69-11 (1)Bending Length measured according toTest C-1381 Bending Length with Sample Width = 25.0 mm, Sample Length =250.0 mm, and waiting time = 8 +/− 2 seconds. (2)Typical Coefficient ofVariance for the Bending Length measurements was approximately 6%.

TABLE 11 Handle-O-Meter Stiffness (1) Stiffness H-O-M Stiffnes H-O-MStiffnes H-O-M MD-Direction MD-Direction CD-Direction Stiffness H-O-MCD-Direction Sample MB Side on top SB Side on top MB Side on top SB Sideon top Number (Grams) (Grams) (Grams) (Grams) Sample 1 30.00 26.23 15.5314.50 69-02 Sample 2 40.17 34.07 21.60 18.10 69-03 Sample 3 39.90 25.5721.00 14.23 69-04 Sample 4 35.03 33.83 20.97 19.77 69-05 Sample 5 28.4727.70 16.23 17.40 69-06 Sample 6 36.17 30.13 20.50 22.23 69-07 Sample 739.60 35.87 26.37 23.97 69-08 Sample 8 43.40 32.37 23.07 22.63 69-09Sample 9 25.53 29.30 15.90 16.73 69-10 Sample 59.33 53.77 35.87 27.83 1069-11 (1) Handle-O-Meter Stiffness measured according to CM-490Handle-O-Meter.

The Bending Length of the composite structures, shown in Table 10 above,model the softness of the cleaning wipes. A low value of Bending Lengthsuggests a wipe that is soft, drapeable and thus easily conformable tothe shape of objects to be cleaned. Thus such a cleaning wipe might beuseful for cleaning the inside of a drinking glass. A wipe with a highbending length would be stiff and strong and thus suggestive of a wipefor cleaning flat surfaces such as table tops or stove tops contaminatedwith dried or baked-on food. The observed range of bending lengths seein Table 10 may suggest minimum difference in softness for this set ofwipes for our invention.

Handle-O-Meter results provide a numerical value to model thecombination of the softness or stiffness and frictional properties ofwipes of our invention. This test suggests a wider difference in theproperties in the prepared samples then seen with the Bending Length. Inparticular, there is a 2× difference in the Handle-O-Meter value betweenSample 10 and, for example, Samples 6 and 9. As noted above, a highervalue of H-O-H suggests a relatively stiff wipe plus some input fromfrictional properties while a low value of H-O-H suggests a softconformable wipe with low input from frictional properties.

The cleaning capability of the cleaning wipes prepared from Samples 1-10were then evaluated for their effectiveness in cleaning stainedsurfaces. Coffee cups used by laboratory members were cleaned by lightlyrubbing the inside of stained cups with wetted wipes selected fromSamples 1-10. The stain from the coffee was removed with no visibledamage to the inside of the cups.

The foregoing examples demonstrate that the inventors have developedeffective cleaning wipes comprising a 100% sustainable polymer content.In certain embodiments, the wipes have a spunbond/meltblown (S/M)structure such that the at least two layers provide different functionsthat can be made in a single step employing up to 100% sustainablepolymer content. In addition, the cleaning wipes in accordance withembodiments of the invention can be engineered to provide differentdegrees or aggressiveness of scrubbing action on one side while theother side can be both strong to support the weaker meltblown abrasiveside while being useful for removal of dust, wiping a surface dry, andbeing soft and smooth to the user's touch. The wipe of our design can bedesigned to be comprised of up to 100% PLA of different molecularweights or optical purities. In a particularly preferred structure oneside of the cleaning wipe is comprised of 100% PLA meltblown fiberswhile the second side is comprised of 100% PLA spunbond fibers. Theaggressiveness of the cleaning wipe, as for example indicated by aproperty such as coefficient of friction, can be governed by the detailsof the meltblown process used to blow the PLA meltblown fibers onto thespunbond nonwoven fabric.

In the following example, a process for preparing a wipe having a verycoarse abrasiveness is shown.

First, a spunbond web comprising 100% PLA bicomponent fibers is made ona pilot line equipped with a Reicofil-4 spinning beam. A press roll (R-4press roll) is positioned on the collection surface downstream of wherethe filaments are to be deposited on the collection surface. An IonisElektrostatik Discharging Electrode E3412 (i.e. ionization bar) extendsover the collection surface in the cross direction and is approximately1 to 3 inches above the collection surface and 2 to 3 inches upstream ofthe R-4 press roll.

A curtain of bicomponent 30/70 NatureWorks Grade 6752/NatureWorks Grade6202/sheath/core fibers is spun and laid on the spunbond machinecollection surface (machine wire) such that the ionization bars asdiscussed above minimize static in the resulting web. Spin beamtemperatures are 235° C. at the extruder and 240° C. at the die. Thespunbond fibers are drawn with a fiber draw speed of 3800 m/min. Theresulting web of bicomponent 30/70 NatureWorks Grade 6752/NatureWorksGrade 6202/sheath/core fibers, is deposited on the machine wire, andthen advances continuously into and through the meltblown web formingstation of the pilot line.

A series of wipes of this invention are made comprised of 100% PLAmeltblown fibers blown from a meltblowing beam directly on the abovedescribed advancing web of 100% PLA spunbond fabric supported on themachine wire. The meltblowing process is first operated with extrudertemperature at 250° C., an Adapter Zone temperature at 250° C. and atemperature at the die of 250° C. The hot air temperature and volumesupplied to the meltblown process are listed in Table 12 below. Thevolume of hot air to the meltblown process is supplied to both sides ofthe curtain of meltblown fibers exiting the die. Other key processconditions are maintained as listed in Table 12 during production of thevery coarse wipes. Basis weight of the finished wipe may be controlledduring trial production by carefully balancing both spunbond andmeltblown extruder thru-put with the speed of the machine wire as wellunderstood by those skilled in the spunmelt (SM) art. As notedpreviously, care should be given when calender bonding the compositeweb.

The resulting webs comprising 100% PLA meltblown fibers deposited on100% bicomponent PLA fibers are then thermally bonded using the calenderpattern roll and anvil (smooth)roll such that the smooth roll contactsthe spunbond side of the SM composite while the patterned roll contactsthe meltblown side of the web. The patterned roll pattern and thebonding pressure and temperatures are carefully selected to providesufficient bonding between spunbond and meltblown fibers to insureadequate abrasion resistance so a minimum number of meltblown orspunbond fibers are deposited on the surface being cleaned but thescrubby surface of the meltblown surface is preserved during the bondingprocess to insure aggressive cleaning of the hard-to-clean surface.

To achieve this balance of properties a calender roll pattern isselected with a % bond area of less than about 30%. For Samples P1-P10,a large Hexadot calender patterned roll is employed with bond area ofapproximately 12%. To prevent sticking and insure ease of releasebetween to surfaces of the wipe web and the calender rolls both thepatterned calender and smooth roll surfaces are treated with anti-stickrelease coating. An example of such a coating is provided by Farrell andGillespie in EP 1,432,860.

A passive static bar is positioned a few cm downstream of the calenderand a second Elektrostatik Discharging Electrode E3412 active ionizationbar is positioned just before the winder are used to manage staticgeneration.

The rolls comprised of the composite web are slit and wound up forcollection at the winder. The resulting composite web may then be usedto manufacture cleaning wipes having an abrasive surface that isconsidered very coarse. The expected abrasiveness of Samples P1-P10 areprovided in Table 13 below. Very course cleaning wipes in accordancewith the invention may be particularly useful for cleaning surface withminimum, if any, damage to the substrate being cleaned and minimumdeposit of abraded fibers from the surface of the cleaning wipe.

TABLE 12 Meltblown Process conditions Supplied Air Maintained AirCalculated Addition Temperture Temperature DCD Meltblown of Sukano toMeltblown to Meltblown Relative Process (relative Suction Basis AdditiveProcess Process Thru-put Air mm above Blower Weight S546-Q1 Sample No.(° C.) (° C.) (RPM) (m³/hr) the wire) (RPM) (GSM) (%) P-1 270 242-252 20200 400 800 10.7 0.5 P-2 270 242-252 20 150 360 800 10.7 0.5 P-3 270242-252 20 150 400 800 10.7 0.5 P-4 (1) 300 272-282 20 1000 180 120010.7 0.5 P-5 (1) 300 272-282 20 1200 180 1200 10.7 0.5 P-6 (1) 300272-282 20 1350 180 1200 10.7 0.5 P-7 (1) 315 287-297 20 1000 180 120010.7 0.5 P-8 (1) 315 287-297 20 1200 180 1200 10.7 0.5 P-9 (1) 315287-297 20 1350 180 1200 10.7 0.5 P-10 (1) 315 287-297 20 1350 180 120010.7 0.0 (1) Meltblown process condition is producing shot. Meltblownshot is a coarse nonuniform layer of meltblown containing randomglobules of PLA interconnected with the normal meltblown strands. Suchrandom globules significantly increase the roughness of the meltblownsurface.

TABLE 13 Kinetic Coefficient of Friction Coefficient of Friction MDDirection (1) (2) Coefficient of Friction MD Coefficient of FrictionMeltblown Side Direction (1) MD Direction (1) against MeltblownMeltblown Side against Spunbond Side against Sample No. Side (3) SmoothSteel (4) Smooth Steel (5) P-1 1.15 0.07 0.05 P-2 1.15 0.07 0.05 P-31.25 0.07 0.05 P-4 1.10 0.07 0.05 P-5 1.20 0.07 0.05 P-6 1.30 0.07 0.05P-7 1.30 0.07 0.05 P-8 1.40 0.07 0.05 P-9 1.50 0.07 0.05 P-10 1.60 0.070.05 (1) Coefficient of Friction is measured according to Method C-1231Coefficient of Friction. Average of three tests. Load cell = 100 N,Clamps Distance = 138.5 mm; Crosshead Speed = 200 mm/minute, (2) TypicalCoefficient of Variance for the Coefficient of Friction is approximately10%. (3) Bottom of sled is covered with experimental wipe with meltblownside facing down against a surface covered by a second layer of the wipewith meltblown surface of the wipe facing up. (4) Bottom of sled iscovered with experimental wipe with meltblown side facing down against asurface of smooth steel. (5) Bottom of sled is covered with experimentalwipe with spunbond side facing down against a surface of smooth steel.

Modifications of the invention set forth herein will come to mind to oneskilled in the art to which the invention pertains having the benefit ofthe teachings presented in the foregoing descriptions and the associateddrawings. Therefore, it is to be understood that the invention is not tobe limited to the specific embodiments disclosed and that modificationsand other embodiments are intended to be included within the scope ofthe appended claims. Although specific terms are employed herein, theyare used in a generic and descriptive sense only and not for purposes oflimitation.

SUMMARY OF THE CLAIMS

In one embodiment, a cleaning wipe having a high sustainable polymercontent is provided in which the cleaning wipe comprises a fibrous layercomprising fibers comprised of a melt spinnable sustainable polymer; andan abrasive layer comprising meltblown fibers comprised of a meltspinnable sustainable polymer, the abrasive layer defining an outersurface of the cleaning wipe, and having a plurality of abrasivestructures formed thereon in which the abrasive structures compriseconglomerated fibers, meltblown shot, fibers having average diametersgreater than 4 micrometers and fibers having a tortuous geometry, andwherein the melt spinnable sustainable polymer content of the cleaningwipe is at least 50 weight % by weight of the cleaning wipe.

In one embodiment according to the preceding paragraph, the meltspinnable sustainable polymer content of the cleaning wipe is at least60% by weight, based on the total weight of the cleaning wipe.

In one embodiment according to one or more of the two precedingparagraphs, the melt spinnable sustainable polymer content of thecleaning wipe is at least 65% by weight, based on the total weight ofthe cleaning wipe.

In one embodiment according to one or more of the preceding threeparagraphs, the melt spinnable sustainable polymer content of thecleaning wipe is at least 70% by weight, based on the total weight ofthe cleaning wipe.

In one embodiment according to one or more of the preceding fourparagraphs, the melt spinnable sustainable polymer content of thecleaning wipe is at least 75% by weight, based on the total weight ofthe cleaning wipe.

In one embodiment according to one or more of the preceding fiveparagraphs, the melt spinnable sustainable polymer content of thecleaning wipe is at least 80% by weight, based on the total weight ofthe cleaning wipe.

In one embodiment according to one or more of the preceding sixparagraphs, the melt spinnable sustainable polymer content of thecleaning wipe is at least 85% by weight, based on the total weight ofthe cleaning wipe.

In one embodiment according to one or more of the preceding sevenparagraphs, the melt spinnable sustainable polymer content of thecleaning wipe is at least 90% by weight, based on the total weight ofthe cleaning wipe.

In one embodiment according to one or more of the preceding eightparagraphs, the melt spinnable sustainable polymer content of thecleaning wipe is at least 95% by weight, based on the total weight ofthe cleaning wipe.

In one embodiment according to one or more of the preceding nineparagraphs, the melt spinnable sustainable polymer content of thecleaning wipe is 100% by weight, based on the total weight of thecleaning wipe.

In one embodiment according to one or more of the preceding tenparagraphs, the fibrous layer comprises a spunbond nonwoven fabric.

In one embodiment according to one or more of the preceding elevenparagraphs, the fibrous layer comprises a polylactic acid (PLA).

In one embodiment according to one or more of the preceding twelveparagraphs, the meltblown fibers comprise a polylactic acid (PLA).

In one embodiment according to one or more of the preceding thirteenparagraphs, the meltblown fibers are self-bonded to the fibrous layer.

In one embodiment according to one or more of the preceding fourteenparagraphs, the fibrous layer has been thermally bonded to the abrasivelayer via a patterned calender roll.

In one embodiment according to one or more of the preceding fifteenparagraphs, an outer surface of the meltblown web includes a bondingpattern formed thereon.

In one embodiment according to one or more of the preceding sixteenparagraphs, the bonding pattern covers less than 30% of a surface areaof the abrasive layer.

In one embodiment according to one or more of the preceding twoparagraphs, the bonding pattern covers from about 10 to 20% of a surfacearea of the abrasive layer.

In one embodiment according to one or more of the preceding threeparagraphs, the bonding pattern covers from about 10 to 15% of a surfacearea of the abrasive layer.

In one embodiment according to one or more of the preceding nineteenparagraphs, an outer surface of the wipe exhibits a kinetic coefficientof friction that is at least 0.2 as measured in accordance with MethodC-1231 Coefficient of Friction, and in which in the measurement an outersurface of the meltblown web is positioned in a face-to-face relationwith an outer surface of an identical meltblown web.

In one embodiment according to one or more of the preceding twentyparagraphs, an outer surface of the cleaning wipe exhibits a kineticcoefficient of friction that is from 0.2 to 0.49, 0.5 to 0.79, 0.8 to0.99, or greater than 1.0 as measured in accordance with Method C-1231Coefficient of Friction, and in which in the measurement an outersurface of the meltblown web is positioned in a face-to-face relationwith an outer surface of an identical meltblown web.

In one embodiment according to one or more of the preceding twenty-oneparagraphs, the cleaning wipe has a basis weight from about 15 to 100g/m², such as a basis weight from about 30 to 60 g/m².

In one embodiment according to one or more of the preceding twenty-twoparagraphs, the fibrous layer has a basis weight from about 15 to 30g/m², and the abrasive layer has a basis weight from about 15 to 30g/m².

In one embodiment according to one or more of the preceding twenty-threeparagraphs, the meltblown fibers have an average fiber diameter greaterthan about 4 micrometers.

In one embodiment according to one or more of the preceding twenty-fourparagraphs, the meltblown fibers have an average fiber diameter fromabout 4 to 8.5 micrometers, from about 6 to 8 micrometers, from about8.5 to 10.5 micrometers, from about 10.5 to 12 micrometers, or fromabout 12.5 to 25 micrometers.

In one embodiment according to one or more of the preceding twenty-fiveparagraphs, the fibrous layer comprises a spunbond nonwoven fabriccomprising continuous monocomponent filaments.

In one embodiment according to one or more of the preceding twenty-sixparagraphs, the fibrous layer comprises a spunbond nonwoven fabriccomprising continuous bicomponent filaments.

In one embodiment according to the preceding paragraph, the bicomponentfilaments comprise a core comprising PLA and a sheath comprising PLA,such as an embodiment in which the PLA of the sheath and the PLA of thecore have a different melt flow rate from each other, or have the samemelt flow rate as each other.

In one embodiment according to one or more of the preceding twenty-sevenparagraphs, the fibers of the spunbond nonwoven fabric comprisebicomponent filaments having a core comprising PLA and a sheathcomprising a synthetic polymer, such as an embodiment in which thesynthetic polymer is a polyolefin, such as polyethylene orpolypropylene, or a polyester.

In one embodiment according to one or more of the preceding twenty-eightparagraphs, the fibrous layer comprises a spunbond nonwoven fabriccomprising a plurality of continuous filaments wherein the sustainablepolymer content of the continuous filaments is at least 50%.

In one embodiment according to one or more of the preceding twenty-nineparagraphs, the fibrous layer comprises a spunbond nonwoven fabriccomprising a plurality of continuous filaments wherein the sustainablepolymer content of the continuous filaments is at least 60%.

In one embodiment according to one or more of the preceding thirtyparagraphs, the fibrous layer comprises a spunbond nonwoven fabriccomprising a plurality of continuous filaments wherein the sustainablepolymer content of the continuous filaments is at least 70%.

In one embodiment according to one or more of the preceding thirty-oneparagraphs, the fibrous layer comprises a spunbond nonwoven fabriccomprising a plurality of continuous filaments wherein the sustainablepolymer content of the continuous filaments is at least 80%.

In one embodiment according to one or more of the preceding thirty-oneparagraphs, the fibrous layer comprises a spunbond nonwoven fabriccomprising a plurality of continuous filaments wherein the sustainablepolymer content of the continuous filaments is at least 90%.

In one embodiment according to one or more of the preceding thirty-twoparagraphs, the fibrous layer comprises a spunbond nonwoven fabriccomprising a plurality of continuous filaments wherein the sustainablepolymer content of the continuous filaments is at least 100%.

In one embodiment according to one or more of the preceding thirty-threeparagraphs, the meltblown fibers are a blend of PLA and a reclaimedsynthetic polymer.

In one embodiment according to one or more of the preceding thirty-fourparagraphs, the meltblown fibers are a blend of reclaimed PLA and areclaimed synthetic polymer.

In one embodiment according to one or more of the preceding thirty-fiveparagraphs, the fibrous layer comprises a spunbond nonwoven fabriccomprising a plurality of fibers that are bonded to each other to form acoherent web, and wherein one or more of the meltblown fibers or thefibers of the fibrous layer comprise a blend of a polylactic acid (PLA)and at least one alkane sulfonate, such as a secondary alkane sulfonate.

In one embodiment according to the preceding paragraph, the blend ispresent at a surface of the plurality of fibers.

In one embodiment according to one or more of the two precedingparagraphs, the at least one alkane sulfonate comprises an alkane chainhaving from C₁₀-C₁₈, and wherein at least one of the secondary carbonsof the alkane chain includes a sulfonate moiety.

In one embodiment according to one or more of the preceding threeparagraphs, the at least one alkane sulfonate has one of the followingstructures:

wherein m+n is a number between 7 and 16, and X is independently a C₁-C₄alkyl or absent.

In one embodiment according to one or more of the preceding fourparagraphs, the at least one alkane sulfonate has the followingstructure:

wherein m+n is a number between 8 and 15.

In one embodiment according to the preceding five paragraphs, the blendis present at a surface of the plurality of fibers.

In one embodiment according to one or more of the preceding sixparagraphs, the at least one alkane sulfonate comprises an alkane.

In one embodiment according to one or more of the preceding sevenparagraphs, m+n is a number between 11 and 14.

In one embodiment according to one or more of the preceding eightparagraphs, the at least one alkane sulfonate comprises a salt of sodiumor potassium.

In one embodiment according to one or more of the preceding nineparagraphs, the at least one alkane sulfonate is present in an amountranging from about 0.0125 to 2.5 weight percent, based on the totalweight of the fiber.

In one embodiment according to one or more of the preceding tenparagraphs, the fibers of the spunbond nonwoven fabric have asheath/core bicomponent arrangement in which the blend is present in thesheath, and wherein the alkane sulfonate is present in the sheath in anamount ranging from about 0.1 to 0.75 weight percent, from about 0.2 to0.6 weight percent, or from about 0.3 to 0.4 weight percent, based onthe total weight of the sheath.

A process for preparing a cleaning wipe according to one or more of thepreceding forty-nine paragraphs comprising the steps of providing aspunbond nonwoven fabric comprising fibers comprised of a melt spinnablesustainable polymer; blowing a stream of meltblown fibers comprising amelt spinnable sustainable polymer onto a surface of the spunbondnonwoven fabric to form an abrasive layer of the composite web, whereinthe meltblown fibers are blown under processing conditions that formabrasive structures on a surface of the composite web; and bonding thecomposite web, and wherein a melt spinnable sustainable polymer contentof the composite web is at least 50% by weight of the composite web.

In additional aspects, a process for preparing a composite web for useas a cleaning wipe having a high sustainable polymer content is providedin which the process comprises: providing a spunbond nonwoven fabriccomprising fibers comprised of a melt spinnable sustainable polymer;blowing a stream of meltblown fibers comprising a melt spinnablesustainable polymer onto a surface of the spunbond nonwoven fabric toform an abrasive layer of the composite web, wherein the meltblownfibers are blown under processing conditions that form abrasivestructures on a surface of the composite web; and bonding the compositeweb, and wherein a melt spinnable sustainable polymer content of thecomposite web is at least 50% by weight of the composite web.

In one embodiment according to the preceding paragraph, the meltspinnable sustainable polymer content of the composite web is at least60% by weight, based on the total weight of the composite web.

In one embodiment according to one or more of the preceding twoparagraphs, the melt spinnable sustainable polymer content of thecomposite web is at least 60% by weight, based on the total weight ofthe composite web.

In one embodiment according to one or more of the preceding threeparagraphs, the melt spinnable sustainable polymer content of thecomposite web is at least 70% by weight, based on the total weight ofthe composite web.

In one embodiment according to one or more of the preceding fourparagraphs, the melt spinnable sustainable polymer content of thecomposite web is at least 75% by weight, based on the total weight ofthe composite web.

In one embodiment according to one or more of the preceding fiveparagraphs, the melt spinnable sustainable polymer content of thecomposite web is at least 80% by weight, based on the total weight ofthe composite web.

In one embodiment according to one or more of the preceding sixparagraphs, the melt spinnable sustainable polymer content of thecomposite web is at least 85% by weight, based on the total weight ofthe composite web.

In one embodiment according to one or more of the preceding sevenparagraphs, the melt spinnable sustainable polymer content of thecomposite web is at least 90% by weight, based on the total weight ofthe composite web.

In one embodiment according to one or more of the preceding eightparagraphs, the melt spinnable sustainable polymer content of thecomposite web is at least 95% by weight, based on the total weight ofthe composite web.

In one embodiment according to one or more of the preceding nineparagraphs, the melt spinnable sustainable polymer content of thecomposite web is 100% by weight, based on the total weight of thecomposite web.

In one embodiment according to one or more of the preceding tenparagraphs, the fibers of the spunbond nonwoven fabric comprise apolylactic acid (PLA).

In one embodiment according to one or more of the preceding elevenparagraphs, the meltblown fibers comprise a polylactic acid (PLA).

In one embodiment according to one or more of the preceding twelveparagraphs, the process further comprises a step of self-bonding themeltblown fibers to the spunbond nonwoven fabric and/or a step ofthermally bonding the spunbond nonwoven fabric to the abrasive layer viaa patterned calender roll.

In one embodiment according to one or more of the preceding thirteenparagraphs, the abrasive layer includes a bonding pattern formedthereon.

In one embodiment according to one or more of the preceding fourteenparagraphs, the bonding pattern covers less than 30% of a surface areaof the abrasive layer.

In one embodiment according to one or more of the preceding twoparagraphs, the bonding pattern covers from about 10 to 20% of a surfacearea of the abrasive layer.

In one embodiment according to one or more of the preceding threeparagraphs, bonding pattern covers from about 10 to 15% of a surfacearea of the abrasive layer.

In one embodiment according to one or more of the preceding sixteenparagraphs, an outer surface of the abrasive layer exhibits a kineticcoefficient of friction that is at least 0.2 as measured in accordancewith Method C-1231 Coefficient of Friction, and in which in themeasurement an outer surface of the meltblown web is positioned in aface-to-face relation with an outer surface of an identical abrasivelayer.

In one embodiment according to the preceding paragraph, an outer surfaceof the abrasive layer exhibits a kinetic coefficient of friction that isfrom 0.2 to 0.49, from 0.5 to 0.79, from 0.8 to 0.99, or greater than1.0 as measured in accordance with Method C-1231 Coefficient ofFriction, and in which in the measurement an outer surface of theabrasive layer is positioned in a face-to-face relation with an outersurface of an identical abrasive layer.

In one embodiment according to one or more of the preceding eighteenparagraphs, the meltblown fibers have an average fiber diameter greaterthan about 4 micrometers, such as from about 4 to 8.5 micrometers, fromabout 6 to 8 micrometers, from about 8.5 to 10.5 micrometers, from about10.5 to 12 micrometers, or from about 12.5 to 25 micrometers.

In one embodiment according to one or more of the preceding nineteenparagraphs, the spunbond nonwoven fabric comprises continuousmonocomponent filaments.

In one embodiment according to one or more of the preceding twentyparagraphs, the spunbond nonwoven fabric comprising continuousbicomponent filaments.

In one embodiment according to the preceding paragraph, the bicomponentfilaments comprise a core comprising PLA and a sheath comprising PLA,such as an embodiment in which the PLA of the sheath and the PLA of thecore have a different melt flow rate from each other, or the PLA of thesheath and the PLA of the core have the same melt flow rate. In someembodiments according to the preceding paragraph, the bicomponentfilaments comprise a core comprising a synthetic polymer and a sheathcomprising PLA, such as a sheath comprising PLA and a core comprising asynthetic polymer, such as a polyolefin (e.g., polyethylene orpolypropylene) or a polyester. In other embodiments according to thepreceding paragraph, the bicomponent filaments comprise a sheathcomprising a synthetic polymer and a core comprising PLA, such as a corecomprising PLA and a sheath comprising a synthetic polymer, such as apolyolefin (e.g., polyethylene or polypropylene) or a polyester.

In one embodiment according to one or more of the preceding twenty-oneparagraphs, the spunbond nonwoven fabric comprises a plurality ofcontinuous filaments wherein the sustainable polymer content of thecontinuous filaments is at least 50%, such as at least 60%, at least70%, at least 80%, at least 90%, or 100%.

In one embodiment according to one or more of the preceding twenty-twoparagraphs, the meltblown fibers are a blend of PLA and a reclaimedsynthetic polymer.

In one embodiment according to one or more of the preceding twenty-threeparagraphs, the meltblown fibers are a blend of reclaimed PLA and areclaimed synthetic polymer.

In one embodiment according to one or more of the preceding twenty-fourparagraphs, the spunbond nonwoven fabric and the meltblown fiberscomprise a blend of a polylactic acid (PLA) and at least one secondaryalkane sulfonate.

In one embodiment according to one or more of the preceding twenty-fiveparagraphs, the blend is present at a surface of the fibers.

In one embodiment according to one or more of the preceding twenty-sixparagraphs, the at least one secondary alkane sulfonate comprises analkane chain having from C₁₀-C₁₈, and wherein at least one of thesecondary carbons of the alkane chain includes a sulfonate moiety.

In one embodiment according to one or more of the preceding twenty-sevenparagraphs, the at least one secondary alkane sulfonate has one of thefollowing structures:

wherein m+n is a number between 7 and 16, and X is independently a C₁-C₄alkyl or absent.

In one embodiment according to one or more of the preceding twenty-eightparagraphs, the blend is present at a surface of the fibers.

In one embodiment according to one or more of the preceding twenty-nineparagraphs, the at least one secondary alkane sulfonate the at least onesecondary alkane sulfonate has the following structure:

wherein m+n is a number between 8 and 15.

In one embodiment according to one or more of the preceding thirtyparagraphs, m+n is a number between 11 and 14.

In one embodiment according to one or more of the preceding thirty-oneparagraphs, the at least one secondary alkane sulfonate comprises a saltof sodium or potassium.

In one embodiment according to one or more of the preceding thirty-twoparagraphs, the at least one secondary alkane sulfonate is present in anamount ranging from about 0.0125 to 2.5 weight percent, based on thetotal weight of the fiber, such as an amount ranging from about 0.1 to0.75 weight percent, from about 0.2 to 0.6 weight percent, or from about0.3 to 0.4 weight percent, based on the total weight of the sheath.

In one embodiment according to one or more of the preceding thirty-threeparagraphs, the step of providing a spunbond nonwoven fabric comprisesproviding a stream of molten or semi-molten melt spinnable sustainablepolymer; forming a plurality of continuous filaments comprising the meltspinnable sustainable polymer; depositing the plurality continuousfilaments onto a collection surface; and exposing the plurality ofcontinuous filaments to ions.

Additional aspects of the invention are directed to a system forpreparing a composite web having a high sustainable content, the systemcomprising: a first source of a melt spinnable sustainable polymerconfigured to provide a stream of molten or semi-molten sustainablepolymer resin; a spunbond spin beam in fluid communication with thefirst source of the melt spinnable sustainable polymer, the spin beamconfigured to extrude and draw a plurality of continuous filaments; acollection surface disposed below an outlet of the spin beam onto whichthe continuous filaments are deposited to form a spunbond nonwovenfabric; a second source of a melt spinnable sustainable polymerconfigured to provide a second stream of molten or semi-moltensustainable polymer resin; a meltblown spin beam disposed downstream ofthe spunbond spin beam, and in fluid communication with the secondsource of the melt spinnable sustainable polymer, the meltblown spinbeam configured to extrude a plurality of meltblown fibers that aredeposited on the spunbond nonwoven fabric; and a calender positioneddownstream of the meltblown spin beam.

In one embodiment of the system according to the preceding claim, thesystem further comprises a first ionization source disposed downstreamof a point at where the continuous filaments are deposited on thecollection surface, and upstream of the meltblown spin beam, wherein thefirst ionization source is positioned and arranged to expose thecontinuous filaments to ions.

In one embodiment according to the preceding claim, the system furthercomprises a second ionization source disposed proximate to the calender.

In one embodiment according to one or more of the preceding two claims,the system further comprises a source of a secondary alkane sulfonatethat is in fluid communication with one or more of the first and secondsources of melt spinnable sustainable polymer.

1. A cleaning wipe having a high sustainable polymer content comprising:a fibrous layer comprising fibers comprised of a melt spinnablesustainable polymer; and an abrasive layer comprising meltblown fiberscomprised of a melt spinnable sustainable polymer, the abrasive layerdefining an outer surface of the cleaning wipe, and having a pluralityof abrasive structures formed thereon in which the abrasive structurescomprise conglomerated fibers, meltblown shot, fibers having averagediameters greater than 4 micrometers and fibers having a tortuousgeometry, and wherein the melt spinnable sustainable polymer content ofthe cleaning wipe is at least 50 weight % by weight of the cleaningwipe, and wherein said outer surface of the wipe exhibits a kineticcoefficient of friction that is at least 0.2.
 2. The cleaning, wipe ofclaim 1, wherein the melt spinnable sustainable polymer content of thecleaning wipe is at least 60% by weight, based on the total weight ofthe cleaning wipe.
 3. The cleaning wipe of claim 1, wherein the fibrouslayer comprises a spunbond nonwoven fabric.
 4. The cleaning wipe ofclaim 1, wherein the fibrous layer comprises a polylactic acid (PLA). 5.The cleaning wipe of claim 1, wherein the meltblown fibers comprise apolylactic acid (PLA).
 6. The cleaning wipe of claim 1, wherein themeltblown fibers are self-bonded to the fibrous layer.
 7. The cleaningwipe of claim 1, wherein the fibrous layer has been thermally bonded tothe abrasive layer via a patterned calender roll.
 8. The cleaning wipeof claim 1, wherein an outer surface of the meltblown web includes abonding pattern formed thereon.
 9. The cleaning wipe of claim 8, whereinh bonding pattern covers less than 30% of a surface area of the abrasivelayer.
 10. The cleaning wipe of claim 1, wherein said outer surface ofthe wipe exhibits a kinetic coefficient of friction from 0.2 to 0.49 asmeasured in accordance with Method 01231 Coefficient of Friction, and inwhich in the measurement an outer surface of the meltblown web ispositioned in a face-to-face relation with an outer surface of anidentical meltblown web.
 11. The cleaning wipe of claim 1, wherein thecleaning wipe has a basis weight from about 15 to 100 g/m².
 12. Thecleaning wipe of claim 1, wherein the meltblown fibers have an averagefiber diameter greater than about 4 micrometers.
 13. The cleaning wipeof claim 1, wherein the fibrous layer comprises a spunbond nonwovenfabric comprising continuous monocomponent filaments and/or continuousbicomponent filaments.
 14. The cleaning wipe of claim 13, whereinfilaments are bicomponent filaments comprise a core comprising PLA and asheath comprising PLA, and wherein the PLA of the sheath and the PLA ofthe core have a different melt flow rate from each other.
 15. Thecleaning wipe of claim 13, wherein the filaments are bicomponentfilaments comprise a core comprising a synthetic polymer and a sheathcomprising PLA, and wherein the bicomponent filaments comprise a corecomprising PLA and a sheath comprising a synthetic polymer comprising apolyolefin or a polyester.
 16. The cleaning wipe of claim 1, wherein themeltblown fibers are a blend of PLA and a reclaimed synthetic polymer.17. The cleaning wipe according to claim 1, wherein the fibrous layercomprises a spunbond nonwoven fabric comprising a plurality of fibersthat are bonded to each other to form a coherent web, and wherein one ormore of the meltblown fibers or the fibers of the fibrous layer comprisea blend of a polylactic acid (PLA) and at least one alkane sulfonate.18. The cleaning wipe of claim 17, wherein the at least one alkanesulfonate comprises an alkane chain having from C₁₀-C₁₈, and wherein atleast one of the carbons of the alkane chain includes a sulfonatemoiety.
 19. The cleaning wipe of claim 17, wherein the at least onealkane sulfonate has one of the following structures:

wherein m+n is a number between 7 and 16, and X is independently a C₁-C₄alkyl or absent.
 20. The cleaning wipe of claim 17, wherein the at leastone alkane sulfonate comprises a secondary alkane sulfonate has thefollowing structure:

wherein m+n is a number between 8 and
 15. 21. The cleaning wipe of claim17, wherein the at least one alkane sulfonate is present in an amountranging from about 0.0125 to 2.5 weight percent, based on the totalweight of the fiber.
 22. A process for preparing a composite web for useas a cleaning wipe having a high sustainable polymer content, theprocess comprising: providing a spunbond nonwoven fabric comprisingfibers comprised of a melt spinnable sustainable polymer; blowing astream of meltblown fibers comprising a melt spinnable sustainablepolymer onto a surface of the spunbond nonwoven fabric to form anabrasive layer of the composite web having an outer surface, wherein themeltblown fibers are blown under processing conditions that formabrasive structures on a surface of the composite web, and wherein saidouter surface exhibits a kinetic coefficient of friction that is atleast 0.2; and bonding the composite web, and wherein a melt spinnablesustainable polymer content of the composite web is at least 50% byweight of the composite web.
 23. The process according to claim 22,wherein the fibers of the spunbond nonwoven fabric comprise a polylacticacid (PLA), and the meltblown fibers comprise a polylactic acid (PLA).